ndrive hl user's manual

Dedicated to the Science of Motion Aerotech, Inc. 101 Zeta Drive, Pittsburgh, PA, 15238 Phone: 412-963-7470 Fax: 412-963-7459

www.aerotech.com

Ndrive HL Users Manual

P/N: EDU176 (Revision: 1.08b)

Product names mentioned herein are used for identification purposes only and may be trademarks of their respective companies. © Aerotech, Inc. 2005-2007

Product Registration Register online at: http://www.aerotech.com/prodreg.cfm

United States Headquarters:

Phone: (412) 967-6440 Fax: (412) 967-6870 Email: [email protected] United Kingdom:

Phone: +44 118 940 9400 Fax: +44 118 940 9401 Email: [email protected]

Technical Support

Germany:

Phone: +49 911 967 9370 Fax: +49 911 967 93720 Email: [email protected]

1.00 June 20, 2003 1.01 February 9, 2004 1.02 May 27, 2004 1.03 July 26, 2004 1.04 September 1, 2004 1.05 September 23, 2004 1.06 November 22, 2005 1.07 January 4, 2006 1.08b October 31, 2007

Revision History

Ndrive HL Users Manual Table of Contents

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TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION ................................................1-1 1.1. Feature Summary .....................................................................1-2 1.2. Connection Overview................................................................1-3 1.3. Ndrive HL Block Diagram..........................................................1-4 1.4. Ordering Information .................................................................1-5 1.5. Electrical Specifications ............................................................1-6 1.6. Mechanical Specifications.........................................................1-9 1.7. Environmental Specifications..................................................1-10

CHAPTER 2: INSTALLATION and CONFIGURATION ..............2-1 2.1. Safety Procedures and Warnings .............................................2-1 2.2. Power Connections...................................................................2-2

2.2.1. Control Power Connections (-AUXPWR) ....................2-2 2.2.2. Motor Power Connections ...........................................2-3 2.2.3. Motor Connections (TB101).........................................2-4 2.2.4. I/O and Signal Wiring Requirements ...........................2-4

2.3. Emergency Stop Sense Input (TB201) .....................................2-5 2.3.1. Typical ESTOP Interface .............................................2-6

2.4. Motor and Feedback Connections............................................2-7 2.4.1. DC Brush Motor in Torque Mode Configuration ..........2-7 2.4.2. DC Brush Motor with Tachometer Feedback

Configuration................................................................2-8 2.4.3. Brushless Motor Configuration ....................................2-9 2.4.4. Stepper Motor Configuration......................................2-14

2.5. Encoder Feedback Connections.............................................2-15 2.5.1. Encoder Phasing........................................................2-16

2.6. End of Travel (EOT) Limit Input Connections .........................2-17 2.6.1. End of Travel (EOT) Limit Phasing ............................2-17

2.7. Communication Channel Settings ..........................................2-18 2.8. Connecting Multiple Ndrive HLs .............................................2-19 2.9. PC Configuration and Operation Information..........................2-20

CHAPTER 3: TECHNICAL DETAILS.......................................3-1 3.1. Auxiliary I/O Connector (J205)..................................................3-1

3.1.1. Secondary Encoder Channel (J205)............................3-3 3.1.2. User Outputs 8-11 (J205) ............................................3-4 3.1.3. User Inputs 8-11 (J205) ...............................................3-5 3.1.4. High Speed User Inputs 12-13 (J205) .........................3-6 3.1.5. Analog Input 0 (J205)...................................................3-6 3.1.6. Analog Output 0 (J205)................................................3-6

3.2. Position Synchronized Output (PSO) / Laser Firing .................3-7 3.2.1. Single Axis Laser Firing .............................................3-11

3.3. Motor Feedback (J207)...........................................................3-12 3.3.1. End of Travel Limit Inputs ..........................................3-13 3.3.2. Hall-Effect and Thermistor Inputs ..............................3-14 3.3.3. Brake Output ..............................................................3-15 3.3.4. Encoder Interface.......................................................3-15

3.4. RS-232 / RS-422 Port (J206)..................................................3-20 3.5. FireWire Bus (J201, J202, J203) ............................................3-22

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3.6. Voltage-to-Current Mode Operation .......................................3-23 3.6.1. Parameter Setup and Hardware Configuration .........3-24 3.6.2. Saving Parameters to the Flash Memory on the

Drive...........................................................................3-24 3.6.3. Operation ...................................................................3-25 3.6.4. Faults .........................................................................3-25

CHAPTER 4: OPTIONS ........................................................... 4-1 4.1. IOPSO and IOPSOH Option Boards ....................................4-1

4.1.1. Brake Configuration Jumpers ......................................4-2 4.1.2. Analog Outputs (TB301) ..............................................4-3 4.1.3. Brake / Relay (TB301) .................................................4-4 4.1.4. Analog Inputs (TB302).................................................4-9 4.1.5. User Power Connector (TB303) ................................4-10 4.1.6. Opto-Isolated Outputs (TB304)..................................4-10 4.1.7. Opto-Isolated Inputs (TB305) ....................................4-12 4.1.8. PSO / Absolute Encoder Interface (J301) .................4-14 4.1.9. SSI Net (2 channel) (J302, J303) .............................4-17

4.2. DUALPSO and TRIPLEPSO Laser Firing Options.............4-19 4.2.1. PSO Tracking Rate Configuration .............................4-20

4.3. ENET (Ethernet) Option J204...............................................4-22 4.4. RDP Resolver Input ..............................................................4-23

4.4.1. Resolver/Inductosyn Setup........................................4-24

CHAPTER 5: ACCESSORIES.................................................. 5-1 5.1. Standard Interconnection Cables .............................................5-1 5.2. Joystick Interface ......................................................................5-5 5.3. Handwheel Interface.................................................................5-9

CHAPTER 6: TROUBLESHOOTING ....................................... 6-1 6.1. Problems, Causes, and Solutions.............................................6-1 6.2. Ndrive HL Control Board Test Points .......................................6-2 6.3. Ndrive HL Control Board Assembly..........................................6-3 6.4. Ndrive HL Motor Power Board Assembly .................................6-5 6.5. Ndrive HL Power Supply Board Assembly ...............................6-7 6.6. LED Indicators ..........................................................................6-9 6.7. JTAG Programming Connector ..............................................6-10 6.8. Fuse / Battery Replacement ...................................................6-11 6.9. Preventative Maintenance ......................................................6-12

6.9.1. Cleaning.....................................................................6-12

APPENDIX A: GLOSSARY of TERMS..................................... A-1

APPENDIX B: WARRANTY and FIELD SERVICE .................. B-1

APPENDIX C: MANUAL UPDATES ......................................... C-1 B.1. Current Changes...................................................................... C-1 B.2. Archive of Changes.................................................................. C-2

INDEX ...................................................................................Index-1

READERS COMMENTS...............................................Comment-1 ∇ ∇ ∇

Ndrive HL Users Manual List of Figures

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LIST OF FIGURES

Figure 1-1. Ndrive HL Networked Digital Drive ...........................................1-1 Figure 1-2. Ndrive HL Hardware .................................................................1-3 Figure 1-3. Ndrive HL Functional Diagram..................................................1-4 Figure 1-4. Ndrive HL Dimensions ..............................................................1-9

Figure 2-1. -AUXPWR Option .....................................................................2-2 Figure 2-2. Motor Power Connections.........................................................2-3 Figure 2-3. ESTOP Sense Input (TB201)....................................................2-5 Figure 2-4. Typical Emergency Stop Circuit................................................2-6 Figure 2-5. DC Brush Motor in Torque Mode Configuration .......................2-7 Figure 2-6. DC Brush Motor Wiring with Tachometer .................................2-8 Figure 2-7. Brushless Motor Configuration .................................................2-9 Figure 2-8. Hall-Effect Feedback Connections .........................................2-11 Figure 2-9. Hall-Effect Feedback Inputs in the Nstat Utility.......................2-11 Figure 2-10. Motor Phasing.........................................................................2-13 Figure 2-11. Stepper Motor Configuration...................................................2-14 Figure 2-12. Encoder Feedback Connections.............................................2-15 Figure 2-13. Encoder Phasing Reference Diagram ....................................2-16 Figure 2-14. Encoder and Hall signals in the Nstat.exe Utility Program .....2-16 Figure 2-15. End of Travel Limit input Connections ....................................2-17 Figure 2-16. Limit Inputs in the Nstat Utility.................................................2-17 Figure 2-17. Recommended Star Daisy Chain Configuration.....................2-19 Figure 2-18. FireWire Daisy Chain ..............................................................2-20

Figure 3-1. Secondary Encoder Channel (J205).........................................3-3 Figure 3-2. User Outputs (J205)..................................................................3-4 Figure 3-3. All User Inputs 8-13 (J205) .......................................................3-5 Figure 3-4. Advanced 1 - 3 Axis Firing ........................................................3-9 Figure 3-5. Data Capture/Data Update Modes .........................................3-10 Figure 3-6. PSO Diagram Basic Single Axis Firing ................................3-11 Figure 3-7. End of Travel Limit Inputs .......................................................3-13 Figure 3-8. Hall-Effect and Thermistor Inputs (J207) ................................3-14 Figure 3-9. Line Driver Encoder Interface Standard (J207) ...................3-16 Figure 3-10. Optional MXH Analog Encoder Interface (J207) ....................3-19 Figure 3-11. RS-232/RS-422 Connector (J206)..........................................3-21 Figure 3-12. Normal Operation....................................................................3-23 Figure 3-13. Stand-Alone Configuration......................................................3-23

Figure 4-1. IOPSO Option Board Location................................................4-1 Figure 4-2. IOPSO Option Board (690D1579 Rev. A) ..............................4-1 Figure 4-3. IOPSOH Option Board (690D1623 Rev. 0) ............................4-2 Figure 4-4. Analog Output Connector (TB301) ...........................................4-3 Figure 4-5. Brake Connected to TB301.......................................................4-5 Figure 4-6. Brake Connected to J207 .........................................................4-6 Figure 4-7. Diode Suppression for DC Brake Systems...............................4-7 Figure 4-8. RC Suppression for DC Brake Systems...................................4-8 Figure 4-9. Optional Analog Input Connector (TB302)................................4-9 Figure 4-10. Connecting Outputs in Current Sinking Mode ........................4-11

List of Figures Ndrive HL Users Manual

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Figure 4-11. Connecting Outputs in Current Sourcing Mode......................4-11 Figure 4-12. Inputs Connected in Current Sourcing Mode .........................4-13 Figure 4-13. Inputs Connected in Current Sinking Mode............................4-13 Figure 4-14. Absolute Encoder Interface (J301) .........................................4-15 Figure 4-15. PSO Interface (J301 and TB303) ...........................................4-16 Figure 4-16. (RS-485) Absolute Encoder Interface (J301) .........................4-16 Figure 4-17. J301/J302/J303.......................................................................4-18 Figure 4-18. Two / Three Axis Laser Firing Interconnection .......................4-19 Figure 4-19. PSO Tracking Rate Block Diagram ........................................4-20 Figure 4-20. Ethernet Interface (J204) ........................................................4-22 Figure 4-21. Resolver Option Assembly (690D1599 Rev. 0)......................4-24 Figure 4-22. Analog Output Connector (TB301) .........................................4-25 Figure 4-23. Resolver Located at Maximum of SIN Signal .........................4-27 Figure 4-24. Rotating the Resolver (to see a circle) ...................................4-28 Figure 4-25. Optimized Resolver Feedback Configuration.........................4-29

Figure 5-1. Joystick Interface ......................................................................5-5 Figure 5-2. Single Axis Joystick Interface to J205 of the Ndrive HL ...........5-6 Figure 5-3. Single Axis Joystick Interconnect to J205 of the Ndrive

HL..............................................................................................5-7 Figure 5-4. Two-Axis Joystick Interface to the I/O on the IOPSO

Option........................................................................................5-7 Figure 5-5. Two-Axis Joystick Connection to the I/O on the IOPSO

Option........................................................................................5-8 Figure 5-6. Handwheel Interconnection to J205 of the Ndrive HL ..............5-9 Figure 5-7. Handwheel with Flying Leads (no connector).........................5-10 Figure 5-8. BBA32 Interface used to connect a Handwheel with

flying leads (no connector)......................................................5-10

Figure 6-1. Ndrive HL Control Board Assembly (690D1577 Rev. A)..........6-3 Figure 6-2. Ndrive HL Motor Power Board, (690D1589 Rev 0) ..................6-5 Figure 6-3. Ndrive HL Power Supply Board, (690D1588 Rev -) .................6-7

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Ndrive HL Users Manual List of Tables

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LIST OF TABLES Table 1-1. Ndrive HL Models and Voltage Configurations.........................1-5 Table 1-2. Electrical Specifications ............................................................1-6 Table 1-3. Ndrive HL Series Amplifier Current Limitations ........................1-8

Table 2-1. Optional Aux Supply AC Input (for external E-Stop).................2-2 Table 2-2. Main Supply AC Power Input Connections...............................2-3 Table 2-3. TB101 Motor Power Output Connections .................................2-4 Table 2-4. Electrical Noise Suppression Devices ......................................2-5 Table 2-5. Ndrive HL Switch Settings (S2)...............................................2-18 Table 2-6. FireWire Card and Cable Part Numbers.................................2-19

Table 3-1. Auxiliary I/O Connector Pin Assignment (J205) .......................3-1 Table 3-2. Auxiliary I/O Mating Connector (J205)......................................3-2 Table 3-3. Auxiliary Encoder Pin Assignment on Connector (J205)..........3-3 Table 3-4. User Outputs Pin Assignment on Connector (J205).................3-4 Table 3-5. User Inputs Pin Assignment on Connector (J205) ...................3-5 Table 3-6. High Speed User Inputs Pin Assignment on Connector

J205 ..........................................................................................3-6 Table 3-7. Auxiliary I/O Connector Pin Assignment (J205) .......................3-6 Table 3-8. Auxiliary I/O Connector Pin Assignment (J205) .......................3-6 Table 3-9. PSO Encoder Signal Sources and Pre-Scaling Methods.........3-7 Table 3-10. PSO Output Sources ................................................................3-7 Table 3-11. Motor Feedback Connector Pin Assignment (J207)...............3-12 Table 3-12. Motor Feedback Mating Connector (J207) .............................3-12 Table 3-13. End of Travel Limit Inputs Pin Assignment on Connector

J207 ........................................................................................3-13 Table 3-14. Hall-Effect Inputs Pin Assignment on Connector J207...........3-14 Table 3-15. Brake Output Pin Assignment on ConnectorJ207 ..................3-15 Table 3-16. Motor Feedback Connector Pin Assignment (J207)..............3-15 Table 3-17. MXH Option Specifications .....................................................3-18 Table 3-18. J206 RS-232 / RS-422 Connector Pin Assignment................3-20 Table 3-19. RS-232 / RS-422 Port Mating Connector (J206) ....................3-20 Table 3-20. J201, J202, J203 FireWire Connector Pin Assignment ..........3-22

Table 4-1. IOPSO Option Board Jumpers ...............................................4-1 Table 4-2. IOPSOH Output Device Numbers ..........................................4-2 Table 4-3. Analog Output Connector Pin Assignment (TB301) .................4-3 Table 4-4. Voltage and Current Specifications (TB301) ............................4-4 Table 4-5. Brake / Relay Connector Pin Assignment (TB301) ..................4-5 Table 4-6. Brake / Relay Connector Pin Assignment (J207) .....................4-5 Table 4-7. Optional Analog Input Connector Pin Assignmentt

(TB302) .....................................................................................4-9 Table 4-8. User Power Connector Pin Assignment (TB303) ...................4-10 Table 4-9. Opto-Isolated Output Connector Pin Assignment

(TB304) ...................................................................................4-10 Table 4-10. Output Specifications (TB304) ................................................4-11 Table 4-11. Opto-Isolated Input Connector Pin Assignment (TB305) .......4-12

List of Tables Ndrive HL Users Manual

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Table 4-12. PSO/Absolute Encoder Interface Connector Pin Assignment (J301) ..................................................................4-14

Table 4-13. PSO / Absolute Encoder Mating Connector (J301)................4-14 Table 4-14. Laser Output Opto-Isolator Specifications..............................4-15 Table 4-15. J302, J303 2-Channel SSI Net Connector Pin

Assignment .............................................................................4-17 Table 4-16. SSI Net Cable Part Numbers..................................................4-20 Table 4-17. Ethernet Connector Pin Assignment (J204) ...........................4-22 Table 4-18. NConnect I/O Cable part Numbers.........................................4-22 Table 4-19. Resolver Connector Pin Assignment (J1, J2).........................4-23 Table 4-20. Resolver Mating Connector (15-Pin Male D-Style) ................4-23 Table 4-21. Resolver Jumper Configuration ..............................................4-23 Table 4-22. Resolver Test Points...............................................................4-24 Table 4-23. External Power Pin Assignment (J403) ..................................4-24

Table 5-1. Standard Interconnection Cables .............................................5-1 Table 5-2. Combined Motor & Feedback Cables.......................................5-2 Table 5-3. Individual Motor Cables ............................................................5-3 Table 5-4. Individual Feedback Cables......................................................5-4

Table 6-1. Amplifier Faults, Causes, and Solutions...................................6-1 Table 6-2. Ndrive HL Control Board Test Point .........................................6-2 Table 6-3. Ndrive HL Control Board Jumper Selections............................6-4 Table 6-4. Ndrive HL Motor Power Board Jumper Selections...................6-6 Table 6-5. Ndrive HL Motor Power Board Fuse Information......................6-6 Table 6-6. Ndrive HL Motor Power Board Test Point Information .............6-6 Table 6-7. Jumper Selections (Line Voltage) on Power Supply

Board.........................................................................................6-7 Table 6-8. Jumper Selections (Bus Voltage) on Power Supply

Board.........................................................................................6-7 Table 6-9. Ndrive HL Power Supply Board Jumper Selections .................6-8 Table 6-10. Ndrive HL Power Supply Board Fuse Information....................6-8 Table 6-11. LED Indicator Description .........................................................6-9 Table 6-12. JTAG Programming Connector Internal (P10) ....................6-10 Table 6-13. Ndrive HL Power Supply Board Fuse Information,

(690D1588) .............................................................................6-11 Table 6-14. Ndrive HL Motor Power Board Fuse Information,

(690D1589) .............................................................................6-11 Table 6-15. Battery Replacement Part Number (Ndrive HL Control

Board) .....................................................................................6-11 Table 6-16. Preventative Maintenance ......................................................6-12

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Ndrive HL Users Manual Declaration of Conformity

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DECLARATION OF CONFORMITY Manufacturer’s Name and Address:

Aerotech, Inc. 101 Zeta Drive Pittsburgh, PA 15238-2897

Declares that the product: Ndrive HL Conforms to the following product specifications, with the exceptions listed below. Safety: EN 61010-1:2001 Safety Requirements Use: This product is intended for light industrial manufacturing or laboratory use. and complies with 73/23/EEC low voltage directive. Notes concerning EN 61010-1: • Voltages greater than 60 Volts may be present inside the unit after a discharge time

of 5 seconds. • The unit must be installed within an enclosure with construction compliant unlimited

circuits. • The end user is responsible for meeting the final protective ground requirements. • The AC power inlet located on the front (and control power on the top, if present) of

the unit is the power disconnect. The end user is responsible for determining and providing a supply disconnect for the system.

• The end user is responsible for preventing unexpected startup. • Connection requirements are described in the technical documentation provided with

the product. The end user is responsible for making the proper connections and meeting any required interlock requirements for the product application.

• The end user must provide protection concerning power interruption / restoration, if required.

• The end user must provide earth fault current protection, if required. • The end user must provide protection against lightning and power switching surges, if

required. • Control and Emergency Stop requirements are to be determined and provided by the

end user. • Wire and cabling provided with the unit meet Aerotech’s electrical and listed

environmental requirements. The end user must meet the final requirements.

Pittsburgh, PA David F. Kincel_________________________

April, 2004 Quality Assurance Manager

Alex R. Weibel ___________________________

Engineer Verifying Compliance

Ndrive HL Users Manual Declaration of Conformity

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EMC Requirements:

The use of shielded cables is required to reduce radiated emissions. The cable shields must be connected to the metal back shell of D-type connectors, or to the nearest frame ground connection for other type connectors. The following modifications will help ensure CE compliance: • Install a snap-on Ferrishield ferrite attenuator, P/N SS28B2034, on the FireWire cable at the unit. • Use a FireWire card with inductive common mode filters, such as the Aerotech NFIRE-PCI or Siig

NN-403P12. These modifications may not be necessary in the final installation of the product. Since the unit is a component, designed to be integrated with other electronics, EMC testing must be conducted on the final product configuration.

Failure to follow these procedures may result in serious injury, damage and/or excessive emissions or reduced immunity of the equipment.

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Ndrive HL Users Manual Introduction

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CHAPTER 1: INTRODUCTION Aerotechs Network Digital Linear Drive (Figure 1-1) (and PWM Ndrive CP, HP, MP, and Nservo, Npaq) complement the Automation 3200 System. Connected via the IEEE-1394 (FireWire®) communication bus, these drives provide deterministic behavior, auto-identification, and easy software setup from the Nmotion SMC software controller. Featuring a high-speed Harvard architecture DSP, the drives are linear for eliminating EMI/RFI emissions and have fully digital current and servo loops providing up to an 8 kHz servo loop closure, 32 MHz line driver encoder data rate, and an optional Ethernet port for access to third party networked I/O solutions. Additionally, one 18 bit analog output and one 16 bit analog input is standard. The Ndrive HL also features an optional on-board brake relay, programmable resolution multiplication up to x65,536, with a 200 kHz maximum amplified sine wave input frequency, and up to three-axis Position Synchronized Outputs (laser firing). In addition, the use of the commercially standard FireWire communication link makes integration to the Automation 3200 network plug-n-play easy.

This product is intended for light industrial manufacturing or laboratory use.

Figure 1-1. Ndrive HL Networked Digital Drive

Introduction Ndrive HL Users Manual

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1.1. Feature Summary

• Software configurable for brush (torque/current and tachometer mode) and brushless motor operation

• Bipolar 40 or 80 VDC bus power supply

• Fully isolated power stage

• 5 VDC, 500 mA user output power for encoder and Hall effect signals, etc.

• Two mounting orientations optimized for heat transfer or minimal panel space utilization

• Full protection against the following failure modes:

1. Control supply under voltage

2. Continuous current overload

3. Power stage bias supply under-voltage

4. Power stage output short circuit (phase to phase and phase to ground)

5. DC bus over voltage

6. IGBT device over temperature sense

• Line driver square wave or analog sine wave quadrature encoder primary position and velocity feedback

• Line driver square wave auxiliary quadrature encoder input or output for PSO (laser firing), etc.

• 4 opto-isolated user outputs standard

• 6 opto-isolated user inputs standard, 2 of which are high speed

• 2 differential analog inputs (one standard and one available with the IOPSO option)

• 2 analog inputs (one standard and one available with the IOPSO option)



1.2. Connection Overview

The Ndrive HL consists of a power connection (motor power and input power), three FireWire ports, an optional Ethernet connection, an RS-232/RS-422 connector, LED indicator lamps and two D-style connectors for Auxiliary I/O (15 and 26 pin) and Motor Feedback (25 pin). An IOPSO/-IOPSOH option is also available, shown below (J301-J303, TB301-TB305), which has connections for PSO, absolute encoder, SSI Net, analog I/O, digital I/O, and user power. Refer to Figure 1-2 for locations.

Figure 1-2. Ndrive HL Hardware



1.3. Ndrive HL Block Diagram

The standard package includes the bus power supply that operates from standard AC line voltage (100/115/208/230 factory configured). The power supply is included with the standard package for off-line operation without the need for an isolation transformer. Figure 1-3 is a functional diagram including options. In addition, a soft start circuit is included to prevent high inrush currents.

Figure 1-3. Ndrive HL Functional Diagram



1.4. Ordering Information

The Ndrive HL is available in three base models with continuous power, ranging from 675 to 1,350 watts. A list of these models, and the available voltage configurations, are shown in Table 1-1

Table 1-1. Ndrive HL Models and Voltage Configurations

Model Standard Bus Voltage

Peak Output Current

Continuous Output Current (peak)

Ndrive HL-20-40 ±40 VDC 20A 10A Ndrive HL-10-80 ±80 VDC 10A 5A Ndrive HL-10-40 ±40 VDC 10A 5A Options

IOPSO and IOPSOH

- One additional 18-bit analog outputs (±10 Volts) - One additional 16-bit differential analog inputs (±10 Volts) - One fail safe brake (or user) relay output - Eight optically isolated logic inputs (5 24 VDC), user defined

as current sourcing or sinking. - Two bi-directional RS-422 encoder inputs/outputs (SSI Net) - One absolute/RS-485 encoder interface for secondary encoder

channel - Optically isolated laser firing (PSO) output - Eight in/out optically isolated current sourcing/sinking logic

outputs (5 - 24 VDC); rated for 1 ampere on the -IOPSOH option.

DUALPSO Two axis Position Synchronized Output (Laser Firing) TRIPLEPSO Three axis Position Synchronized Output (Laser Firing)

PSOOPTO1 Opto-isolator for PSO, requires the IOPSO option (<5V, high speed, high current, HCPL2601)

PSOOPTO2 Opto-isolator for PSO, requires the IOPSO option (<15V, high speed, low current, 6N136)

PSOOPTO3 Opto-isolator for PSO, requires the IOPSO option (<30V, low speed, high current, 4N33)

PSOOPTO4 Opto isolator for PSO (5-25VDC, 40kHz, 50mA, TIL117-M)

MXH Programmable encoder multiplier up to x2,048, supports PSO (laser firing) and encoder quadrature output

ENET 10/100BASE-T Ethernet port for I/O expansion MCK-NDRIVE Mating connector kit for J206 and J207 (J205 is always provided)

AUXPWR Auxiliary 85-240 VAC input to power logic circuitry. Required for "keep alive" or 20-80 VDC bus operation. 20-120 VDC operation requires external transformer to generate 15-85 VAC bus power input.

JI Optional Industrial Joystick



1.5. Electrical Specifications

The electrical specifications for the Ndrive HL are listed in Table 1-2.

Table 1-2. Electrical Specifications Description Units 20-40 10-40 10-80

Main Supply Input Voltage VAC 100, 115, 200, 230 (model dependent)

Main Supply Input Frequency Hz 50-60 Main Supply Inrush Current A 23 23 23 Optional Supply Input Voltage VAC 85-240 Optional Supply Input Frequency Hz 50-60 Optional Supply Maximum Input Power Watts 100 Voltage Output (brushless)(1) VDC 80 80 160 Output Voltage (brush) VDC 40 40 80 Current Peak Output (2) Apk 20 10 10 Current Continuous Output(2) Apk 10 5 5 Power Peak Dissipation (per phase) Watts 360 Power Peak Output (3) Watts 1,350 675 1,350 Power Continuous Output Watts 675 337 675 Power Amplifier Gain (each phase) A/V 2 1 1 Power Amplifier Bandwidth(4) kHz 2 Minimum Load Inductance mH 0 Minimum Load Resistance (line-to-neutral) Ohms 0.5 Operating Temperature °C 0 to 50 Storage Temperature °C -30 to 85

Standard 22.0 (9.98) Weight

IOPSO or -IOPSOH option lb (kg)

22.2 (10.07)

1. Ndrive HLs can drive each of its phases rail to rail since the drive supply for each phase is not derived from the +/- bus voltages.

2. Peak and continuous output current is load dependent, see Table 1-3.

3. This specification based on the output power transistors in the saturated (e.g., full on) condition.

4. Into an Aerotech BLM-203-A linear forcer (RLL = 4Ω , LLL = 3.2 mH)



Table 1-2. Electrical Specifications (continued) Specification Description

Brushless Modes of Operation Brush (Current/Torque and tachometer Mode)

Hall A-Pin 10, Hall B-Pin 5, Hall C-Pin 11: Hall effect device inputs for commutation, 0 to 5 VDC, internal pull-up, 10K input. Commutation signals used with brushless motors to provide motor rotation position information to the amplifier. This allows the amplifier to steer the three phases of the motor currents in such a fashion to provide rotation of the motor in the desired direction at the desired speed. TTL level input.

Feedback Inputs

Sine/Sine-N, Pin 17/Pin 18, Cosine/Cosine-N, Pin 14/Pin 15: Encoder input 0 to 5VDC, internal pull-up, 10K input.

Power Inputs (AC1, AC2) AC input: AC1, AC2, earth ground ( ), 50-60 Hz, single phase.

5V-Pin 16: On board 5V power supply. 250 mA max. output. Auxiliary Power Outputs (AL1, AL2)

5V-Pin 3: On board 5V power supply. Pin 3 is intended for powering an encoder. Ndrive HL can supply up to 500 mA of current total to user devices. Output short circuit Peak over current DC bus over voltage RMS over current

Over temperature Control power supply under voltage

Protective Features

Power stage bias supply under voltage Designed to EN61010/UL3101

Isolation Optical and transformer isolation between control and power stages.

Indicator (Power) LED indicates drive power. Indicator (Enabled) LED indicates drive enabled.



Table 1-3. Ndrive HL Series Amplifier Current Limitations

Ndrive HL10-40 Tambient = 25OC

Ndrive HL10-40Tambient = 50OC



Ndrive HL10-80 Tambient = 25OC


RL-L IPK1)

Limit

IPK-CONT2)

Limit IPK

Limit IPK-CONTLimit

IPK Limit

IPK-CONTLimit

IPK Limit

IPK-CONTLimit

IPK Limit

IPK-CONT Limit

IPK Limit

IPK-CONTLimit

(Ohms) (Amps) (Amps) (Amps) (Amps) (Amps) (Amps) (Amps) (Amps) (Amps) (Amps) (Amps) (Amps)0.5 10.0 5.00 10.0 4.50 14.5 6.50 14.5 4.50 6.5 3.25 6.5 2.25 1 10.0 5.00 10.0 4.50 16.0 7.00 16.0 4.50 7.0 3.25 7.0 2.25

1.5 10.0 5.00 10.0 4.75 18.5 7.50 18.5 4.75 7.0 3.25 7.0 2.25 2 10.0 5.00 10.0 4.75 20.0 7.75 20.0 4.75 7.0 3.25 7.0 2.25

2.5 10.0 5.00 10.0 5.00 20.0 8.25 20.0 5.00 7.5 3.25 7.5 2.25 3 10.0 5.00 10.0 5.00 20.0 9.00 20.0 5.25 7.5 3.50 7.5 2.25

3.5 10.0 5.00 10.0 5.00 20.0 10.00 20.0 5.25 7.5 3.50 7.5 2.25 4 10.0 5.00 10.0 5.00 20.0 10.00 20.0 5.50 8.0 3.50 8.0 2.25

4.5 10.0 5.00 10.0 5.00 * 10.00 * 6.00 8.0 3.50 8.0 2.25 5 10.0 5.00 10.0 5.00 * 10.00 * 6.50 8.5 3.50 8.5 2.25

5.5 10.0 5.00 10.0 5.00 * 10.00 * 7.25 8.5 3.50 8.5 2.25 6 10.0 5.00 10.0 5.00 * 10.00 * 10.00 9.0 3.75 9.0 2.25

6.5 10.0 5.00 10.0 5.00 * 10.00 * 10.00 10.0 3.75 10.0 2.25 7 10.0 5.00 10.0 5.00 * 10.00 * 10.00 10.0 3.75 10.0 2.25

7.5 10.0 5.00 10.0 5.00 * 10.00 * 10.00 10.0 3.75 10.0 2.25 8 10.0 5.00 10.0 5.00 * 10.00 * 10.00 10.0 3.00 10.0 2.50

8.5 * 5.00 * 5.00 * * * * 10.0 4.00 10.0 2.50 9 * 5.00 * 5.00 * * * * 10.0 4.00 10.0 2.50

9.5 * 5.00 * 5.00 * * * * 10.0 4.00 10.0 2.50 10 * 5.00 * 5.00 * * * * 10.0 4.25 10.0 2.50

10.5 * 5.00 * 5.00 * * * * 10.0 4.25 10.0 2.50 11 * 5.00 * 5.00 * * * * 10.0 4.25 10.0 2.50

11.5 * 5.00 * 5.00 * * * * 10.0 4.50 10.0 2.50 12 * 5.00 * 5.00 * * * * 10.0 4.50 10.0 2.50

12.5 * 5.00 * 5.00 * * * * 10.0 4.75 10.0 2.50 13 * 5.00 * 5.00 * * * * 10.0 4.75 10.0 2.50

13.5 * 5.00 * 5.00 * * * * 10.0 5.00 10.0 2.50 14 * 5.00 * 5.00 * * * * 10.0 5.00 10.0 2.50

14.5 * 5.00 * 5.00 * * * * 10.0 5.00 10.0 2.75 15 * 5.00 * 5.00 * * * * 10.0 5.00 10.0 2.75

15.5 * 5.00 * 5.00 * * * * 10.0 5.00 10.0 2.75 16 * 5.00 * 5.00 * * * * 10.0 5.00 10.0 2.75

16.5 * * * * * * * * * * * *

*Limited by: VBUS/(RLL/2) Definitions:

RLL motor resistance (line-to-line) IPK peak output current that the amplifier will sustain for 1 second when running a three phase

commutated motor IPK-CONT peak value of a continuous sine wave

Notes: IPK limit ensures that an instantaneous current pulse does not harm the output transistors. IPK-CONT limit ensures that the temperature of the amplifier does not reach a value that would harm the

semiconductor devices.



1.6. Mechanical Specifications

Units should be separated from each other and surrounded by one inch of free air space. This will also allow the standard nine-inch (228 mm) FireWire cable to interconnect them.

76.2 [3.00]25.4 [1.00] 23.8 [0.94]127.0 [5.00]

188.

0 [7

.40]

248.

5 [9

.79]

256.

2 [1

0.09

]11

.2 [0

.44]

273.

1 [1

0.75

]

4.7 [0.19] 2.3 [0.09]230.1 [9.06]

255.0 [10.04]

234.

3 [9

.22]

79.9 [3.15]

169.3 [6.67]

40.6 [1.60]

43.8

[1.7

3]

20.7

[0.8

1]18

.1 [0

.71]

Ø4.7 [Ø0.19]

Figure 1-4. Ndrive HL Dimensions

The Ndrive HL case temperature may exceed 75°C in some applications.



1.7. Environmental Specifications

The environmental specifications for the Ndrive HL are listed below.

• Temperature: Ambient

Operating - 5° - 40°C (41° - 104°F)

Storage - -20 70°C (-4 158°F)

• Humidity: Maximum relative humidity is 80% for temperatures up to 31°C. Decreasing linearly to 50% relative humidity at 40°C. Non-condensing.

• Altitude Up to 2000 m.

• Pollution Pollution degree 2 (normally only non-conductive pollution).

• Use Indoor use only.

∇ ∇ ∇

Ndrive HL Users Manual Installation and Configuration


CHAPTER 2: INSTALLATION and CONFIGURATION This section covers the hardware configurations using the switches, jumpers, connectors, and power connections when used with a brush or brushless motor. Wiring, grounding, shielding techniques, and the motor phasing process are also covered.

Aside from the obvious requirements of AC input power and motor wiring, the only other typical requirement is to define the Ndrive HLs communication channel number via switch S2 (see Section 2.7).

2.1. Safety Procedures and Warnings

The following statements apply wherever the Warning or Danger symbol appears within this manual. Failure to observe these precautions could result in serious injury to those performing the procedures and/or damage to the equipment.

If the equipment is used in a manner not specified by the manufacturer, the protection by the equipment may be impaired. The user should practice caution when following the given procedures. Deviation from this may result in damage to the equipment or machinery.

To minimize the possibility of electrical shock and bodily injury, ensure that the motor is decoupled from the mechanical system and no harm to personnel will result if the motor begins to spin.

To minimize the possibility of electrical shock and bodily injury when any electrical circuit is in use, ensure that no person is exposed to the circuitry.

To minimize the possibility of bodily injury, make certain that all electrical power switches (all switches external to the amplifier) are in the off position prior to making any mechanical adjustments.

Installation and Configuration Ndrive HL Users Manual


2.2. Power Connections

The Ndrive HL may powered by one or two separate AC voltages. One for motor bus power and optionally a second for control power, as described in the following two sub-sections. If the optional control power input is present, it must be powered.

2.2.1. Control Power Connections (-AUXPWR) The -AUXPWR option allows the Ndrive HL to remain operational when the motor power is removed, such as when an emergency stop circuit is required. If the Ndrive HL was purchased with the -AUXPWR option, a separate AC input has been included on the amplifier. The internal power supply of the Ndrive HL requires a minimum of 85 VAC input to operate properly. The figure below shows the connection to the AUXPWR AC input. The connection is made to via a three terminal connector. See Section 2.4 for various typical AC wiring options. This optional input is used when an external emergency stop circuit is present. See Section 2.3 for a typical ESTOP wiring configuration.

The AUXPWR control power inputs (AL1, AL2) are optional, but must be powered if present. These inputs are typically used when an external emergency stop circuit is present. Connections to the AL1, AL2 inputs and the protective Ground should be at least 1.62814 mm (#14 AWG) wire rated @ 300 V (3 Amp external fusing may be required for AL2, AL1 is fused internally at 3 Amps).

Figure 2-1. -AUXPWR Option

Table 2-1. Optional Aux Supply AC Input (for external E-Stop) Pin Description Wire Size AL1 Optional 85-240 VAC Control Power Input 1.62814 mm (#14 AWG) AL2 Optional 85-240 VAC Control Power Input 1.62814 mm (#14 AWG)

Protective Ground (Required for Safety) 1.62814 mm (#14 AWG)



2.2.2. Motor Power Connections

Input power to the Ndrive HL is made at the AC1 and AC2 terminals with earth ground connected to (ground). The motor frame and shield connect to (ground) as well. Connections at the AC1, AC2 and Protective Ground connections should be made with 1.62814 mm (#14 AWG) wire rated at 300V.

Figure 2-2. Motor Power Connections

Table 2-2. Main Supply AC Power Input Connections Pin Description Wire Size AC1 115/100/208/230 Volt AC Input 1.62814 mm (#14 AWG) AC2 115/100/208/230 Volt AC Input 1.62814 mm (#14 AWG)

From Earth Ground (Required for Safety) 1.62814 mm (#14 AWG) External fuses or circuit breaker (10 Amperes, time delay type) are required for the AC1 and AC2 AC inputs for optimum protection. The protective devices should be located near the Ndrive HL.



2.2.3. Motor Connections (TB101) The three-phase motor terminal connections are made at connections A, B, C and optionally at RT. The RT connection is only used for brushless motors having a fourth motor lead, as in a Wye configuration. Motor Connections ØA, ØB, ØC and its Protective Ground should be made with 1.62814 mm (#14 AWG) wire rated at 300 V. The motor frame and shield must be connected to (ground) as well. See Section 2.4 for information on connecting each of the supported motor types.

Table 2-3. TB101 Motor Power Output Connections Pin Description Wire Size ØA Phase A Motor Lead 1.62814mm (#14 AWG) ØB Phase B Motor Lead 1.62814mm (#14 AWG) ØC Phase C Motor Lead 1.62814mm (#14 AWG) RT Brushless Motors with Wye connection only 1.62814mm (#14 AWG)

Earth Ground to Motor (Required for Safety) 1.62814mm (#14 AWG)

2.2.4. I/O and Signal Wiring Requirements The I/O, communication, and encoder feedback connections are typically very low power connections. Wire and connectors used for signal wiring should be rated for at least 30 V and have a current capacity of at least .25 Amp. Wires and connectors used for low voltage power connections such as +5V should have a current capacity of at least 1 Amp (encoder feedback +5V supply may require .6 Amps in some applications). In some applications, especially when there are significant wire distances, a larger wire size may be required to reduce the voltage drop that occurs along the wire. This increase may be necessary in order to keep the voltage within a specified range at a remote point.

When signal wiring is in close proximity to wiring operating at voltages above 60 Volts the insulation rating of the signal wiring will also need to be rated for the higher voltage. Signal wiring should have a voltage rating of at least 300 Volts when in proximity to AC power or motor power wiring.



2.3. Emergency Stop Sense Input (TB201)

This input is intended to be activated by an external fail-safe emergency stop circuit. It is not intended to be an emergency stop circuit in itself. It is scaled for an input voltage of 5-24 volts. Using a higher input voltage requires adding an external series resistor to limit the current.

If the ESTOP bit is enabled in the FaultMask axis parameter, the ESTOP input must be driven to prevent the ESTOP fault condition.

For typical ESTOP wiring, see the following two drawings.

Figure 2-3. ESTOP Sense Input (TB201)

Connecting the E-Stop input to a relay or other EMI/RFI noise producing device/circuit, requires one or more noise suppression devices, such as those in Table 2-4, or other appropriate devices.

Table 2-4. Electrical Noise Suppression Devices Device Aerotech P.N. Third party P.N. RC (.1uf / 200 ohm) Network EIC240 Electrocube RG1782-8 Varistor EID160 Littlefuse V250LA40A



2.3.1. Typical ESTOP Interface The user may connect an emergency stop circuit to the Ndrive HL. It will disable power to the motor by removing power to the power stage of the drive, while maintaining power to the control section, as shown in the following Figure 2-4.

Ndrive HLAUXPWR INTERCONNECT

(WITH E-STOP)

SAFTEY

AC LO

AC HI

AU

XP

WR

AC2

AC1

MA

IN

SU

PP

LY

AC1

AC2

Ndrive HLAUXPWR OPTION

INPUT50/60 HZ

115-230VAC

NOTES:

THE AUXPWR OPTION CAN BE USED WHEN THE MAIN SUPPLY (BUS POWER) MUST BE REMOVED DURING AN EMERGENCY STOP CONDITION, WHILE LOGIC (ENCODER) POWER MUST BE MAINTAINED.

FOR THE E-STOP INPUT TO BE ACTIVE, SETUP THE APPROPRIATE FAULTMASK IN THE AXIS PARAMETERS FOR THE DESIRED ACTION WHEN AN E-STOP CONDITION IS PRESENT.

1CR1

TB201 - ESTOP INPUT

2

1 +24V

control relayCR1

USER SUPPLIED

+24VDCSUPPLY

COM

2

E-STOP

1

2

1

coil

1 AC2AU

XP

WR

AC1

2

2

TB201 - ESTOP INPUT

1

MA

IN

SU

PP

LY

AC1

AC2

AUXPWR OPTIONNdrive HL

15A Slow-Blow

15A Slow-Blow

Figure 2-4. Typical Emergency Stop Circuit



2.4. Motor and Feedback Connections

The Ndrive HL can be integrated into a system using three basic configurations: DC Brush (Velocity and Torque mode), brushless or stepper motors. Brush and brushless motors may have two feedback devices.

2.4.1. DC Brush Motor in Torque Mode Configuration The DC brush motor configuration is shown in Figure 2-5. See section 2.5.1. for the correct encoder phasing information if Aerotechs standard cabling is not used.

Figure 2-5. DC Brush Motor in Torque Mode Configuration

2.4.1.1. DC Brush Motor Phasing

If an Aerotech motor is used with Aerotech provided cabling, no motor phasing process is required.

A DC brush motor is phased correctly, when a positive motion command causes clockwise (CW) motor rotation, as viewed looking at the motor from the front mounting flange. This assumes the CntsPerMetricUnit/CntsPerEnglishUnit/CntsPerRotaryUnit axis parameters are set to a positive value. This required phasing, is determined solely by which motor lead is connected to the ØA and ØC motor terminals. Motor phasing is unrelated to the resultant direction of motion commanded from within a motion program. After correctly phasing the motor, you may reverse the motor direction when commanding a positive move from a motion program, by negating the sign of the CntsPerMetricUnit/CntsPerEnglishUnit/CntsPerRotaryUnit axis parameters.

To determine this, connect a voltmeter to the motor leads of an un-powered motor. Rotate the motor by hand clock-wise (CW). Swap the voltmeter connections to the motor until the voltmeter indicates a positive voltage. The motor lead now connected to the positive lead of the voltmeter, is the + motor lead as indicated in the Figure above, and should be connected to the ØA motor terminal. The other motor lead connects to the ØC motor terminal.



2.4.2. DC Brush Motor with Tachometer Feedback Configuration The DC brush motor configuration is shown in Figure 2-6. See section 2.5.1. for the correct encoder phasing information if Aerotechs standard cabling is not used. The tachometer may be connected to TB302 or J205 as shown in the picture below. Note, that tachometer feedback uses analog input 0, so it may not be used when tachometer feedback is used. To configure the axis parameters in this mode, see the "Brush Motors in Velocity Mode" topic in the Nview HMI help.

The analog input that the tachometer is connected to is scaled for ±10V input maximum. The tachometer voltage must not exceed ±10 volts or the velocity loop will become unstable, possible causing a runaway condition. Based upon the tachometer voltage rating, a resistor-scaling network may be required to limit the tachometer voltage to ±10V at maximum speed. If noise is present on the tachometer signal, a high quality 1 uF capacitor may be required across the tachometer leads, before any voltage divider, required to limit the maximum input voltage to the analog input.

The motor and tachometer are correctly phased, when rotated clockwise by hand and the tachometer generates a positive voltage as displayed on analog input 0 and the motors back EMF generates a negative voltage at motor terminal A (with the voltmeter common probe at motor terminal C).

Figure 2-6. DC Brush Motor Wiring with Tachometer



2.4.3. Brushless Motor Configuration This mode is used with a brushless motor only. See section 2.5., if Aerotechs standard cabling is not used, for information on correctly phasing the motor, encoder and Hall feedback devices.

Figure 2-7. Brushless Motor Configuration



2.4.3.1. Brushless Motor Phasing

When configuring the Ndrive HL to run a non-Aerotech brushless motor, the motor leads (A, B and C on TB101) must be correctly connected for proper operation. If an Aerotech motor is used with Aerotech provided cabling, no motor phasing process is required.

If an Aerotech brushless motor is used with the Ndrive HL, motor phase and HALL connections can be easily determined by referring to the system interconnection drawing in Figure 2-7.

Be sure to configure all axes with the Nparam.exe utility before running the A3200\Programs\Samples\MsetDebug.Pgm. See the Getting Started section in the Nview help for configuration information.

An AC brushless motor is correctly phased, when a positive motion command causes clockwise (CW) motor rotation, as viewed looking at the motor from the front mounting flange. This assumes a positive CntsPerMetricUnit/ CntsPerEnglishUnit /CntsPerRotaryUnit axis parameter. This required phasing is determined by which motor lead is connected to the ØA, ØB and ØC motor terminals.

Motor phasing is unrelated to the direction of motion commanded from within a motion program. After correctly phasing the motor, you may reverse the motor direction when commanding a positive move from a motion program, by negating the sign of the CntsPerMetricUnit/CntsPerEnglishUnit/CntsPerRotaryUnit axis parameter.

Motor phasing may be determined by two methods. The first of which, is by actively driving the motor open loop, under program control. The A3200\Programs\Samples\MsetDebug.Pgm may be used for this purpose. The motor phasing is correct when the program causes the motor to move in a positive direction, as defined in Figure 2-13. Swapping any two motor lead connections will correct a reversed motor rotation.

The second method is a non-powered method, whereby the motor is disconnected from the controller and connected in the test configuration as defined in Figure 2-10 This will identify motor (and Hall signal) leads A, B and C. These sequences and the generated output motor phase voltages (motor output connections A, B, and C) are shown in Figure 2-10. The voltages generated are made by moving the motor/forcer by hand in a positive (CW) motion direction.



2.4.3.2. Brushless Motor Hall-Effect Feedback Connections

The Hall-Effect feedback signals on an AC brushless motor are correctly phased when the hall states correspond to the states at each of the electrical angles shown in Figure 2-10 The hall states, which correspond to the electrical angles are indicated in Figure 2-10 A 0 for the given Hall input indicates zero voltage or logic low, where a 1 indicates five volts or logic high. These logic levels may be viewed within the Nstat utility, on the Diagnostic tab, as shown in Figure 2-9.

Figure 2-8. Hall-Effect Feedback Connections

Figure 2-9. Hall-Effect Feedback Inputs in the Nstat Utility



2.4.3.3. Hall-Effect Phasing

For an AC brushless motor with an unknown phase/hall sequence, one of two simple tests can be performed on the motor to determine the proper connections to the Ndrive HL.

Be sure to first configure the axis parameters before running the A3200\Programs\Samples\MsetDebug.Pgm. See the Getting Started section in the Nview help for configuration information.

The first of which, is by actively driving the motor under program control. The A3200\Programs\Samples\MsetDebug.Pgm may be used for this purpose, as well as for motor lead phasing. The hall signal wiring must be swapped until they generate the sequence as defined in the Nview help, which the test program will display. After the hall sequence is correct, the program can then correctly determine if a commutation offset is required. The test program will indicate the required value of the CfgMotOffsetAng axis parameter to correctly phase the motor.

The second method is a non-powered method, whereby the motor is disconnected from the controller and connected in the test configuration as defined in Figure 2-10. This will identify the hall signals (and motor leads) A, B and C. The equipment needed for the non-powered test is a two-channel oscilloscope and three resistors (typically 10 K ohm, 1/2 watt) wired in a Wye configuration.

Before performing the test in Figure 2-10, ensure that the motor leads are completely disconnected from the amplifier.

The tests outlined below do not require that the amplifier be powered since Figure 2-10 illustrates the generated output voltage of the amplifier relative to the input Hall sequences.

Connect the ends of the three resistors to motor terminals A, B, C. Use one channel of the oscilloscope to monitor motor terminal A with respect to the Wye neutral (i.e., the point where all three resistors are connected together). Turn the shaft of the motor CW and note the generated voltage. This voltage represents the phase A to neutral Counter EMF (CEMF). With the second oscilloscope probe, determine the Hall switch that is in phase with this voltage. Similarly, phase B and C should be aligned with the other two Hall switches. This will identify each motor and hall lead set, which are in-phase with each other. Any motor and hall lead set may be phase A. The relative phasing between this set and the other two sets will then determine which is phase B and phase C.

Refer to Figure 2-10 and note the generated output voltages of the amplifier relative to the Hall sequences applied to HALL A, HALL B, and HALL C connections at connector J207. For proper operation, the CEMF generated motor phase voltages should be aligned to the amplifiers generated output voltage with the Hall effect reference sequence shown in Figure 2-10.



Figure 2-10. Motor Phasing



2.4.4. Stepper Motor Configuration This mode is used with a stepper motor only. See section 2.5.1., if Aerotechs standard cabling is not used for information on correctly phasing the motor feedback devices.

Figure 2-11. Stepper Motor Configuration

2.4.4.1. Stepper Motor Phasing Process

A stepper motor is phased correctly when a positive motion command causes the motor to rotate in a clockwise (CW) direction, assuming a positive scaling factor, as determined by the CntsPerMetricUnit/CntsPerEnglishUnit/CntsPerRotaryUnit axis parameter. To correct the phasing, reverse the connections to the θA and θB terminals on the Ndrive HL. This is important because the end of travel (EOT) limit inputs are relative to motor rotation. After correctly phasing the motor, you may reverse the motor direction when commanding a positive move from a motion program, by negating the sign of the CntsPerMetricUnit/CntsPerEnglishUnit/CntsPerRotaryUnit axis parameter.



2.5. Encoder Feedback Connections

One encoder feedback device must be used for all motor types, except for stepper motors. Each of the two encoder channels in the Ndrive HL, accept a differential line driver encoder, or with the -MXH option, the primary encoder channel, J207 accepts an analog sine wave encoder. DC Brush and brushless motors may have a separate position and a velocity feedback device. An analog sine wave encoder may be used with Aerotechs MXH multiplier box to multiply the encoder resolution and simultaneously convert it to a differential line driver encoder signal, acceptable by the Ndrive HL.

Signal shielding is very important and the wiring should be physically isolated from motor, AC power and all other power wiring.

Figure 2-12. Encoder Feedback Connections



2.5.1. Encoder Phasing Figure 2-13 illustrates the required encoder phasing for clockwise motor rotation, or positive forcer movement, through the stationary magnet track. If the motor is not visible, or maybe not be manually moved by hand, it maybe actively driven open loop, under program control, via the A3200\Programs\Samples\MsetDebug.Pgm. This program will move the motor in a positive direction, allowing the position of the encoder to be monitored in the Nstat.exe utility program. It will be displayed on the main Diagnostics tab as the Pos Fdbk item, as shown in Figure 2-14. The program should cause the encoder to produce a more positive position value as the program executes. If it indicates a more negative value, swap the connections to the controllers SIN and the SIN-N encoder inputs, or you may invert the sign of the CfgFbkVelMultiplier and CfgFbkPosMultiplier axis parameters. However, if this axis is configured for dual loop, two feedback devices, one for position and one for velocity feedback, invert only the one axis parameter associated with the incorrectly phased feedback device.

Figure 2-13. Encoder Phasing Reference Diagram

Figure 2-14. Encoder and Hall signals in the Nstat.exe Utility Program



2.6. End of Travel (EOT) Limit Input Connections

End of Travel (EOT) Limits are required to define the end of the physical travel. One of which may also be also used for homing the axis, which defines an absolute reference for the user coordinate system. EOT Limits are relative to positive motion, which is defined as clockwise rotary motion or positive linear motor motion. Positive or clockwise motion is stopped by the CW or clockwise EOT limit input, etc.

Figure 2-15. End of Travel Limit input Connections

Figure 2-16. Limit Inputs in the Nstat Utility

2.6.1. End of Travel (EOT) Limit Phasing If the EOT limits are reversed, swap the connections to the CW and CCW inputs at the J207 connector of the Ndrive HL. The logic level of the EOT limit inputs may be viewed on the Diagnostic tab of the Nstat utility, as shown in Figure 2-15.



2.7. Communication Channel Settings

Each Ndrive HL must have a unique communication channel number defined by switch S2. It is recommended that they be sequential beginning with the first device number. The 1st device as indicated by the switch settings in row 1 of the following table will be configured by the Axis 1 parameters in the Nparam utility. Assuming all axes are selected on the Axis menu in Nparam, they will be the parameters in the first column. The Ndrive HL configured as Row 2 indicates below, will be configured by the axis parameters in column 2 of the Nparam utility, etc.

Information on connecting options such as analog and digital I/O, and laser firing (PSO) is provided in Chapter 4: Options.

Table 2-5. Ndrive HL Switch Settings (S2) Switch Settings (Off is indicated by - )

Ndrive HL # 7 6 5 4 3 2 1 0

1st ! ! ! ! ! ! ! ! 2nd ! ! ! ! ! ! ! - 3rd ! ! ! ! ! ! - ! 4th ! ! ! ! ! ! - - 5th ! ! ! ! ! - ! ! 6th ! ! ! ! ! - ! - 7th ! ! ! ! ! - - ! 8th ! ! ! ! ! - - - 9th ! ! ! ! - ! ! ! 10th ! ! ! ! - ! ! - 11th ! ! ! ! - ! - ! 12th ! ! ! ! - ! - - 13th ! ! ! ! - - ! ! 14th ! ! ! ! - - ! - 15th ! ! ! ! - - - ! 16th ! ! ! ! - - - - 17th ! ! ! - ! ! ! ! 18th ! ! ! - ! ! ! - 19th ! ! ! - ! ! - ! 20th ! ! ! - ! ! - - 21st ! ! ! - ! - ! ! 22nd ! ! ! - ! - ! - 23rd ! ! ! - ! - - ! 24th ! ! ! - ! - - - 25th ! ! ! - - ! ! ! 26th ! ! ! - - ! ! - 27th ! ! ! - - ! - ! 28th ! ! ! - - ! - - 29th ! ! ! - - - ! ! 30th ! ! ! - - - ! - 31st ! ! ! - - - - ! 32nd ! ! ! - - - - -



2.8. Connecting Multiple Ndrive HLs

Following are two interconnection diagrams and a chart showing the part numbers of the FireWire Bus PCI card and the various interconnect cables and their part numbers.

Table 2-6. FireWire Card and Cable Part Numbers Part Number Description NFire-PCI FireWire OHCI compliant PCI interface card NFire-Multi FireWire card, with USB 2.0 and GigaBit Ethernet LAN

NFire-PCI-TI-LP Low Profile OHCI compliant PCI FireWire card NConnect-4500-66 FireWire cable, 4.5 M (15 feet) long, 6 pin to 6 pin NConnect-1800-66 FireWire cable, 1.8 M (6 feet) long, 6 pin to 6 pin NConnect-900-66 FireWire cable, 900 mm (3 feet) long, 6 pin to 6 pin NConnect-381-66 FireWire cable, 381 mm (15 inches) long, 6 pin to 6 pin NConnect-228-66 FireWire cable, 228 mm (9 inches) long, 6 pin to 6 pin

Figure 2-17. Recommended Star Daisy Chain Configuration



Figure 2-18. FireWire Daisy Chain

Before connecting any device to the FireWire bus, the device should be powered up and tested independently to prevent damaging interconnected drives.

Ndrive HLs, CPs, HPs, MPs, Nservos, Nsteps and Npaqs should always have their FireWire cables connected in a star configuration to minimize the FireWire cable lengths, see Figure 2-17.

2.9. PC Configuration and Operation Information

The Getting Started Guide (PN: EDU175), included with the Nmotion SMCs software package, provides a quick start guide with basic information. The Nview help included with the software provides additional information for configuring the Ndrive HL to the PC as well as information on hardware requirements, getting started, utilities and system operation, and on using the Nview HMI user application.

∇ ∇ ∇

Ndrive HL Users Manual Technical Details


CHAPTER 3: TECHNICAL DETAILS

3.1. Auxiliary I/O Connector (J205)

The J205, Auxiliary I/O connector provides 1 analog and 6 digital inputs, 1 analog and 4 digital outputs and a secondary bi-directional RS-422 line driver encoder interface. See the following sub-sections for details on each type of signal within the J205 connector.

Table 3-1. Auxiliary I/O Connector Pin Assignment (J205) Pin # Label Description In/Out/Bi-dir.

1 Auxiliary Sine + Secondary RS-422 Channel - Sine+ Bi-dir. 2 Auxiliary Sine - Secondary RS-422 Channel - Sine- Bi-dir.

3 In 12 + Input 12 High Speed Opto. + (user interrupt)

Input

4 In 12 - Input 12 High Speed Opto. - (user interrupt)

Input

5 In 13 + Input 13 High Speed Opto. + (user interrupt)

Input

6 In 13 - Input 13 High Speed Opto. - (user interrupt)

Input

7 Out 8 Output 8 Output 8 Out 9 Output 9 Output 9 Out 10 Output 10 Output 10 Auxiliary Cosine + Secondary RS-422 Channel - Cosine+ Bi-dir. 11 Auxiliary Cosine - Secondary RS-422 Channel - Cosine- Bi-dir. 12 +5 Volt +5 Volt (500 mA. max.)* Output 13 Analog 0 In+ Analog Input 0 + (Differential) Input 14 Analog 0 In- Analog Input 0 - (Differential) Input 15 Out Com Output Common -

16 Out 11 Output 11 / optional PSO Laser Firing Output

Output

17 In 8 Input 8 Input 18 In 9 Input 9 Input

19 Auxiliary Marker - Secondary RS-422 Channel - Mrk+ / PSO out.

Bi-dir.

20 Auxiliary Marker + Secondary RS-422 Channel - Mrk- / PSO out.

Bi-dir.

21 Common (+5 Volt ) Common (+5 Volt User Supply) - 22 Analog 0 Out Analog Output 0 Output 23 A Gnd Analog Common - 24 In Com Input Common - 25 In 10 Input 10 Input 26 In 11 Input 11 Input

* Total user +5 V power is limited to 500 mA, by an internal re-settable semiconductor fuse.

Technical Details Ndrive HL Users Manual


Table 3-2. Auxiliary I/O Mating Connector (J205) 26 Pin HD D style con. Aerotech Third Party Source Connector ECK01259 Kycon K86-AA-26P Back shell ECK00600 Cinch DA24658 Screw Locks, Qty. 2 EIZ00294 TRW D-20419-16

All of the external power provided by the Ndrive HL to the user is limited to 500 mAmps and protected by a re-settable semiconductor fuse. Should an over-current condition occur, the device will open to protect against the overload. To reset the over-current device, remove the overload condition.

Please note that the inputs and outputs on the Auxiliary connector (J205) begin with number 8, as shown in Table 3-1. Inputs and outputs 0 7 are present on the optional IOPSO, see Chapter 4 for more information.



3.1.1. Secondary Encoder Channel (J205) The encoder channel can be used as an input for master/slave operation (handwheel) or for dual feedback systems or for an encoder input/output for multi-axis laser firing (see Chapter 4 for more information). The EncoderDivider axis parameter configures the input/output state of this encoder channel. This interface may not be multiplied by the MXH option and must be a 5-volt RS-422 line driver encoder. It allows up to an 8 MHz encoder signal (31 nsec. minimum edge separation), producing 32 million counts per second, after times four (x4) quadrature decoding. The Auxiliary Marker output has a .02 us propagation delay typical, when used as the PSO firing output.

See Table 3-2 for the mating connector part number.

Table 3-3. Auxiliary Encoder Pin Assignment on Connector (J205) Pin # Label Description In/Out/Bi. 1 Auxiliary Sine + Secondary RS-422 Channel - Sine+ Bi-directional 2 Auxiliary Sine - Secondary RS-422 Channel - Sine- Bi-directional 10 Auxiliary Cosine + Secondary RS-422 Channel - Cosine+ Bi-directional 11 Auxiliary Cosine - Secondary RS-422 Channel - Cosine- Bi-directional 12 +5 Volt +5 Volt (500mA. max.)* Output

19 Auxiliary Marker - Secondary RS-422 Channel - Mrk+ / PSO out.

Bi-directional

20 Auxiliary Marker + Secondary RS-422 Channel - Mrk- / PSO out.

Bi-directional

21 Common (+5 Volt ) Common (+5 Volt User Supply) -


Figure 3-1. Secondary Encoder Channel (J205)



3.1.2. User Outputs 8-11 (J205) All outputs (Figure 3-2) are rated for 40 volts DC and 80 mAmps per channel. Power dissipation may not exceed 90 mWatts per channel. Figure 4-10 illustrates how toconnect to an output in current sinking mode.

Output 11, shown in Figure 3-2, may be defined as a low-speed PSO (Laser Firing output), however, it is only rated for a maximum output frequency of 1 kHz, with a typical propagation delay of 250 us. The auxiliary marker output on pins 19 and 20 of J205 (see Section 3.1) may be opto-isolated by the user and software configured as the PSO output via the EncoderDivider axis parameter and the PSOCONTROL command, see the Nview help for more information. See Section 3.2 for more information on the PSO option.


Table 3-4. User Outputs Pin Assignment on Connector (J205) Pin # Label Description In/Out/Bi. 7 Out 8 Output 8 Output 8 Out 9 Output 9 Output 9 Out 10 Output 10 Output 12 +5 Volt +5 Volt (500mA. max.)* Output 15 Out Com Output Common -

16 Out 11 Output 11 / optional PSO Laser Firing Output

Output

21 Common (+5 Volt ) Common (+5 Volt User Supply) -


Figure 3-2. User Outputs (J205)



3.1.3. User Inputs 8-11 (J205) All inputs (Figure 3-3), including the high-speed inputs, are scaled for an input voltage of 5-24 volts DC. A higher input voltage requires adding external series resistors to limit the current to 20 milliamps. Figure 4-10 and Figure 4-11 illustrate how to connect to an output in current sourcing and sinking current modes, respectively. Inputs 8-10 may also be used as CW, CCW and Home EOT limit inputs, respectively, by setting bit 22 of the DriveIOConfig axis parameter.


Table 3-5. User Inputs Pin Assignment on Connector (J205) Pin # Label Description In/Out/Bi. 12 +5 Volt +5 Volt (500mA. max.)* Output 17 In 8 Input 8 / CCW EOT Input Input 18 In 9 Input 9 / CW EOT Input Input 21 Common (+5 Volt) Common (+5 Volt User Supply) - 24 In Com Input Common - 25 In 10 Input 10 / Home Input Input 26 In 11 Input 11 Input


Figure 3-3. All User Inputs 8-13 (J205)



3.1.4. High Speed User Inputs 12-13 (J205) All inputs (Figure 3-3), including the high-speed inputs, are scaled for an input voltage of 5-24 volts DC. A higher input voltage requires adding external series resistors to limit the current to 20 milliamps. The high-speed inputs (inputs 12 and 13) have a delay of 50 nanoseconds (typical).


Table 3-6. High Speed User Inputs Pin Assignment on Connector J205 Pin # Label Description In/Out/Bi 3 In 12 + Input 12 High Speed Opto. + (user interrupt) Input 4 In 12 - Input 12 High Speed Opto. - (user interrupt) Input 5 In 13 + Input 13 High Speed Opto. + (user interrupt) Input 6 In 13 - Input 13 High Speed Opto. - (user interrupt) Input 12 +5 Volt +5 Volt (500mA. max.)* Output 21 Common (+5 V) Common (+5 Volt User Supply) - 24 In Com Input Common -


3.1.5. Analog Input 0 (J205) The analog inputs accept a signal within the range of -10 through +10 volts DC. Signals outside this range may damage the input. For analog input technical information, see Section 4.1.4.

Table 3-7. Auxiliary I/O Connector Pin Assignment (J205) Pin # Label Description In/Out/Bi. 13 Analog 0 In+ Analog Input 0 + (Differential) Input 14 Analog 0 In- Analog Input 0 - (Differential) Input 23 A Gnd Analog Common -


3.1.6. Analog Output 0 (J205) The analog output may be programmed to output a signal within the range of -10 through +10 volts DC. For analog output technical information, see Section 4.1.2.


Table 3-8. Auxiliary I/O Connector Pin Assignment (J205) Pin # Label Description In/Out/Bi. 22 Analog 0 Out Analog Output 0 Output 23 A Gnd Analog Common -




3.2. Position Synchronized Output (PSO) / Laser Firing

The Ndrive HL includes a Position Synchronized Output (PSO or Laser Firing) option. This feature may be programmed to generate an output synchronized to axes positions, based upon a user-defined trigger condition, most typically, but not limited to firing a laser. The Ndrive HL offers three levels of laser firing, single axis (std.) and two and three axis. Trigger signals may be derived from the primary encoder channel, secondary encoder channel, either of the two optional SSI Net ports or a software trigger. Both SSI Net ports may provide axes encoder signals or marker signals to/from another Ndrive HL at a maximum of a 20 MHz. data rate (50 nsec. minimum edge separation). Single axis tracking is limited to a 20 MHz. data rate and multi-axis to a 5 MHz. tracking rate. The PSOTRACK command may be used to scale the encoder input signal to limit the maximum tracking rate. The synchronized output pulse is solely generated within sophisticated and versatile high-speed hardware, allowing minimal delays between the trigger condition and the output. Single axis PSO laser firing latency is 200 nanoseconds. DUALPSO and TRIPLEPSO laser firing latency is 275 nanoseconds, not including the propagation delay of the output device. Refer to Figure 3-6 for a basic single-axis block diagram of the PSO capabilities, or Figure 3-4 and Figure 3-5 for a more detailed block diagram of the multi-axis capabilities that also apply to single-axis firing. The output may be either an open-collector output (dedicated PSO output or user output 11) or a differential RS-422 output. The opto-isolated output is available in three different configurations as shown in Table 3-10. Additionally, the PSO options provide Data Capture and Data Update capabilities, also shown in Figure 3-4 and Figure 3-5. For programming information, refer to the Nview HMI Help.

Table 3-9. PSO Encoder Signal Sources and Pre-Scaling Methods

Encoder Signal Source

Max. Data Rate (w/o pre-scalar)

Encoder Input (pre-scalar)

Encoder Output (pre-scalar)

Primary Encoder 32 MHz. PSOTRACK Command

CfgFbkEncQuadDivider axis parameter (MXH only)

Secondary Encoder 32 MHz. PSOTRACK

Command None

SSI Net Ports 1 and 2 20 MHz. PSOTRACK

Command CfgFbkEncMxhSetup axis parameter

Table 3-10. PSO Output Sources

PSO Output Type Maximum Frequency

Standard or Option

Requires User Isolation

High Speed Opto-Isolator (J301) Table 4-13 -IOPSO option No Opto-Isolated Output 11 (J205) 1 kHz Standard No RS-422 Marker output on Sec. Encoder (J205) 10 MHz Standard Yes

The pre-scalar in the block diagram is used to normalize the resolution of axes with different machine step sizes or to scale down (divide) the maximum input frequency to the PSO tracking hardware. The PSO hardware operates in machine counts, so all axes must be scaled, or normalized to like units. This allows a trigger to be generated from a true vectorial position change. Each of the three possible tracking channels has a pre-scalar, which may be used to divide the number of encoder counts on that channel. Each pre-scalar defaults to 1 and may divide the input feedback pulses by up to 1,023.



The trigger condition may be a software trigger under program control, various other hardware triggers, or most typically a user-defined change in vectorial position, on one to three axes. This vectorial position change is monitored via hardware, allowing an output pulse to be generated in less than 275 nanoseconds (200 nsec. for single axis) after the trigger is detected, not including the propagation delay of the output device. This is accomplished via hardware that monitors the designated axes positions, calculates the sum of the squares of the axes positions and compares it to the desired (squared) position trigger value. All of the mathematical squaring of the positions occurs in hardware for speed. The comparison of the squared command to feedback position occurs at an 8 MHz. rate for multi-axis firing and at a 20 MHz. rate for single axis firing. Furthermore, this vectorial position trigger value is queued via a 255 level queue, in hardware to the triggering hardware, with each trigger advancing through the queue to the next trigger value. This allows the trigger value to be specified as a series of incremental trigger points, if desired.

The absolute accuracy is excellent, although, point-to-point accuracy may vary, due to the calculated feedback squared firing distance jumping past the (internally squared) user programmed firing distance. This small error is accumulated and subtracted from the next firing distance, maintaining absolute accuracy. For example, if the user programs a trigger to occur after a vectorial change in position of 5 machine steps. Internally, this is squared, and the axes positions are internally squared and compared to 25. If they are equal to or greater than 25, a trigger event occurs. The comparison occurs at an 8 MHz. rate (125 nano-seconds), so, should the sum of the square of the axes change in position be equal to 9 during a sample period, no trigger occurs. However, on the next sample, the sum of the squares of the axes positions could now be equal to 36. A trigger event would now occur (36 is greater than 25) and the remainder (11) is then stored to be summed with the squared feedback positions during the next sample period.

The output pulse is also user programmable. It may be a single, or multiple pulses per trigger event. It too is generated in hardware and fed from a 255 level queue, allowing trigger events to advance through the queue, varying the output pulse per trigger event.



Figure 3-4. Advanced 1 - 3 Axis Firing

The window modes allow firing to occur, or be enabled, based upon axes being within a user-defined window. This window may be one or two-dimensional. The ± and Enter/Exit Detection block within the block diagram is used to prevent false triggering due to one bit dither on an axis, etc. Window modes may not be pre-scaled as indicated in the block diagram.

The Data Capture and Data Update modes allow data to be captured or written to the I/O on the occurrence of the internal or external trigger. Data Capture mode allows position, digital inputs, etc. to be captured. Data Update mode allows analog or digital outputs to be set by the same trigger. The capture and update modes are defined in Figure 3-5. For a full description of these modes, refer to the Nview HMI help.



These Capture/Update modes, share four FIFO's (queue's) with Window 1 and Window 2, preventing the window-firing modes from being used with the Capture/Update mode. Using a queue from a window, precludes using that window (1 or 2) for firing, however, queues from window 1 may be used for data capture/update mode, while queues from window 2 may be used for window firing purposes. The Capture/Update modes vary for Window 1 and Window 2, see Figure 3-5.

The data capture mode rate for analog inputs is limited to approximately 100,000 samples per second due to A/D conversion rate. The data update mode for analog outputs is limited to 500,000 Hertz due to internal serial bus design constraints.

Figure 3-5. Data Capture/Data Update Modes



3.2.1. Single Axis Laser Firing Single axis firing requires no additional encoder signals and is capable of tracking the axis position at up to a 20 MHz. tracking rate (50 nsec. minimum edge separation). It may be programmed to fire from any available encoder source, see Table 3-9. Single axis firing provides one feature not present with the multi-axes firing option, it allows for directional based firing. This means that you may program a firing distances for the positive and negative motion separately. Single axis window firing and Capture/Update modes may be used with single-axis firing, limited only by the use of the Windows internal shared queue's.

See Figure 3-6 for a basic single-axis block diagram of the PSO capabilities or Figure 3-4 and Figure 3-5 for a more detailed block diagram of the multi-axis capabilities that also apply to single-axis firing.

Figure 3-6. PSO Diagram Basic Single Axis Firing



3.3. Motor Feedback (J207)

The 25-pin D style connector contains all of the required feedback inputs for a servo loop. This connector has inputs for a 3-channel encoder, three limit switches, and three Hall effect devices. Each of these inputs provides feedback for the DSP microprocessor controlled position, velocity and current loops.

See Section 2.5.1. for information on interfacing non-Aerotech motors.

Table 3-11. Motor Feedback Connector Pin Assignment (J207) Pin # Label Description In/Out/Bi. 1 Frame Chassis Frame N/A 2 Thermistor Motor over temperature Thermistor Input 3 +5 Volt +5 Volt Power for Encoder (500mA. max.)* Output 4 Common Signal Common N/A 5 Hall B Hall Effect Sensor B (Brushless Motors only) Input 6 Mkr- Encoder Marker Reference Pulse - Input 7 Mkr+ Encoder Marker Reference Pulse + Input 8 N.C. No Connection N/A 9 N.C. No Connection N/A 10 Hall A Hall Effect Sensor A (Brushless Motors only) Input 11 Hall C Hall Effect Sensor C (Brushless Motors only) Input 12 CW/+Lmt. Clockwise End of travel limit Input 13 Brake - Optional Brake - Output Output 14 Cos+ Encoder Cosine + Input 15 Cos- Encoder Cosine - Input 16 +5 Volt +5V Power for Limit Switches (500mA. max.)* Output 17 Sin+ Encoder Sine + Input 18 Sin- Encoder Sine - Input 19 N.C. No Connection N/A 20 Common Signal Common for Limit Switches N/A 21 Common Signal Common for Encoder N/A 22 Hm.Lmt. Home Switch Input Input 23 N.C. No Connection N/A 24 CCW/-Lmt. Counterclockwise End of travel limit Input 25 Brake + Optional Brake + Output Output


Table 3-12. Motor Feedback Mating Connector (J207) 25-Pin Male D-style Aerotech Third Party Source Connector ECK00101 Cinch P/N DB25P Back shell ECK00656 Amphenol P/N 17-1726-2

All of the external power provided by the Ndrive HL to the user is limited to 500 mAmps and protected by a re-settable semiconductor fuse. Should an over-current condition occur, the device will open to protect against the overload. To reset the over-current device, remove the overload condition.



3.3.1. End of Travel Limit Inputs Two of the three limit inputs are end-of-travel sensing (CW Limit and CCW Limit) while the third is a reference limit (Home Limit). All of the end-of-travel limit inputs accept 5-24 volt DC logic signals. The pin assignment for the connector is shown in the table below.

Alternatively, opto-isolated user inputs 8-10 may be used as the end-of-travel limit inputs, see Section 3.1.3.


Table 3-13. End of Travel Limit Inputs Pin Assignment on Connector J207 Pin # Label Description In/Out/Bi. 12 CW/+Lmt. Clockwise End of travel limit Input 16 +5 Volt +5 Volt Power for Limit Switches (500mA.

max.)* Output

20 Common Signal Common for Limit Switches N/A 22 Hm.Lmt. Home Switch Input Input 24 CCW/-Lmt. Counterclockwise End of travel limit Input


Figure 3-7. End of Travel Limit Inputs



3.3.2. Hall-Effect and Thermistor Inputs The Hall-Effect switch inputs are highly recommended for AC brushless motor commutation but not absolutely required, see the Nview help for more information on axis configuration. The Hall-effect inputs accept 5-24 volt DC logic signals. The pin assignment for the connector is shown in the table below.

The thermistor input is used to detect an over temperature condition in a motor, via a positive temperature coefficient device. That is, as the temperature of the device increases, so does the resistance of the device. Under normal operating conditions, the resistance of the thermistor is low (i.e., 100 ohms). This will be seen as a low input signal. After the temperature causes the thermistors resistance to increase above 1K ohms, the signal will be seen as a logic high, triggering an over temperature fault.


Table 3-14. Hall-Effect Inputs Pin Assignment on Connector J207 Pin # Label Description In/Out/Bi. 2 Thermistor Motor over temperature Thermistor Input 3 +5 Volt +5 Volt Power for Encoder (500mA. max.)* Output 5 Hall B Hall Effect Sensor B (Brushless Motors only) Input 10 Hall A Hall Effect Sensor A (Brushless Motors only) Input 11 Hall C Hall Effect Sensor C (Brushless Motors only) Input 21 Common Signal Common for Encoder N/A


Figure 3-8. Hall-Effect and Thermistor Inputs (J207)



3.3.3. Brake Output The brake output provides a direct connection to the brake the relay on the optional IOPSO board. The brake output will be present on this connector only when the IOPSO option board is present, allowing the brake signal to utilize the existing feedback cable without the need for additional wiring. See Section 4.1.3. in Chapter 4, for more hardware information on the brake output. The brake output may be automatically controlled via the drive, when activated via the BrakeOnDriveDisable axis parameter, or manually toggled via the BRAKE command, see the NView help for more information.


Table 3-15. Brake Output Pin Assignment on ConnectorJ207 Pin # Label Description In/Out/Bi. 13 Brake - Optional Brake Relay - Output Output 25 Brake + Optional Brake Relay + Output Output

3.3.4. Encoder Interface The three encoder signals consists of the following: sine (Sin), cosine (Cos), and marker (Mkr) as well as their complimentary signals: sine-n (Sin-N), cosine-n (Cos-N), and marker-n (Mkr-N).

The encoder interface accepts an RS-422 differential quadrature signal in the range of 0 to 5 Volts DC in line driver format (Section 3.3.4.1). It allows up to an 8 MHz encoder signal (31 nsec minimum edge separation), producing 32 million counts per second, after times four (x4) quadrature decoding.

The encoder interface may be factory configured to accept an analog signal for the MXH (Section 3.3.4.5).

See Section 2.5.1. Encoder Phasing for information on interfacing non-Aerotech motors. See Table 3-12 for the mating connector part number.

Table 3-16. Motor Feedback Connector Pin Assignment (J207) Pin # Label Description In/Out/Bi. 1 Frame Chassis Frame N/A 3 +5 Volt +5 Volt Power for Encoder (500mA. max.)* Output 6 Mkr - Encoder Marker Reference Pulse - Input 7 Mkr + Encoder Marker Reference Pulse + Input 14 Cos + Encoder Cosine + Input 15 Cos - Encoder Cosine - Input 17 Sin + Encoder Sine + Input 18 Sin - Encoder Sine - Input 21 Common Signal Common for Encoder N/A


All external power provided by the Ndrive HL to the user is protected by a re-settable semiconductor fuse. Should an over-current condition occur, the device will open to provide protection against the overload. To reset the over-current device, remove the over-current condition.



3.3.4.1. Line Driver Encoder (Standard)

The primary encoder input is standardly configured for a differential line driver encoder, in the range of 0 to +5 volts. It allows up to an 8 MHz encoder signal (31 nsec minimum edge separation), producing 32 million counts per second, after times four (x4) quadrature decoding. An analog encoder is used with the MXH option; see Figure 3-10 for more information.

Figure 3-9. Line Driver Encoder Interface Standard (J207)

The Ndrive HL is factory configured for either a square wave differential encoder (default), OR an analog encoder (MXH options).



3.3.4.2. MXH Option

The MXH encoder input options are defined for a differential analog encoder in the range of 0 to +5 volts. The maximum encoder input frequency is limited to 200 kHz, or less if the encoder signals are to be output via the SSI Net, see Table 3-17. The MXH multiplies the resolution up to 512 times, in addition to the controllers x4 multiplication, providing a maximum of x 2048 multiplication (8.388607 GHz. Effective data rate), as shown in the first two columns of Table 3-17.

The MXH multiplication factor is determined by the CfgFbkEncMultFactorMXH axis parameter, which is then multiplied x4 additionally by the controller. Each time this axis parameter is changed, the controller will internally re-program its logic. This re-programming cycle will take about 3.5 minutes. The LEDs will indicate that the internal MXH option is being internally erased and then re-programmed, and that the axis may not be enabled during this time. While the MXH option is being erased, the LEDs will indicate the pattern shown to the upper right. When the MXH option is being re-programmed, the LEDs will alternate between the two patterns shown to the lower right.

The Ndrive HL contains digital potentiometers to adjust the gain, offset and phase balance of the analog Sine and Cosine inputs. The digital potentiometer settings are controlled by the CfgFbkEncCosGain, CfgFbkEncCosOffset, CfgFbkEncPhase, CfgFbkEncSineGain, CfgFbkEncSineOffset axis parameters. The MXH option is compatible with the DUALPSO and TRIPLEPSO options. A differential line driver encoder may be used also, see Figure 3-9 for more information.

The specifications for the MXH multiplier option are shown in Table 3-17. The following table indicates the maximum specifications for the MXH option when the signals are output via the SSI Net. Otherwise, the only limit is the maximum input frequency of 200 kHz. See Figure 3-9 for MXH typical input circuitry. The pin assignment is indicated in Table 3-11.



Table 3-17. MXH Option Specifications Applicable only when signals are output via the SSI Net (4) CfgFbkEncMult-

FactorMXH Axis Parameter

Total (1,2)

Multiplication Clock (3) Freq. (MHz)

Max Input (4)

Freq (kHz) Min Edge (4) Separation (µs)

Min Pulse (4)

Width (µs) 40 200 .025 .025 20 200 .05 .05 10 200 .1 .1

10 X40

5 125 .2 .2 40 200 .025 .025 20 100 .05 .05 10 50 .1 .1

50 X200

5 25 .2 .2 40 100 .025 .025 20 50 .05 .05 10 25 .1 .1

100 X400

5 12.5 .2 .2 40 50 .025 .025 20 25 .05 .05 10 12.5 .1 .1

200 X800

5 6.25 .2 .2 40 40 .025 .025 20 20 .05 .05 10 10 .1 .1

250 X1000

5 5 .2 .2 40 20 .025 .025 20 10 .05 .05 10 5 .1 .1

500 X2000

5 2.5 .2 .2

1. Interpolation includes x4 from quadrature i.e., MXH50 has a net interpolation of x200 (x50 from MXH and x4 from quadrature).

2. Configurable via the CfgFbkEncMultFactorMXH axis parameter from 1 to 512 in increments of 1.0, yielding a multiplication from x4 to x2048.

3. Defined by the CfgFbkEncMxhSetup axis parameter, for SSI Net use. Must be limited to 20 Mhz. for PSO tracking applications via the CfgFbkEncQuadDivider axis parameter.

4. Absolute maximum input frequency limited to 200 kHz due to 1.25 MHz sample rate, lesser limit applies only when signals are output via the SSI Net.



Figure 3-10. Optional MXH Analog Encoder Interface (J207)



3.4. RS-232 / RS-422 Port (J206)

Note that the RS-232C and RS-422 (factory option) ports may not be used simultaneously, as they are one physical port, converted to each interface by the appropriate line driver/receiver, as shown in Figure 3-11. Connecting the RS-232 port to a users PC requires only a standard 9-pin RS-232C interconnection cable (not a null modem). Currently, the RS-232C port serves only as a secondary means to upgrade the firmware in the Ndrive HL, which is done primarily through the FireWire port.

Table 3-18. J206 RS-232 / RS-422 Connector Pin Assignment Pin # Label Description In/Out/Bi. 1 Frame Chassis Frame N/A 2 RS-232 TXD RS-232 Transmit Output Output 3 RS-232 RXD RS-232 Receive Input Input 4 RS-422 TXD+ RS-422 Transmit Output + Output 5 Common Signal Common N/A 6 RS-422 TXD- RS-422 Transmit Output - Output 7 RS-422 RXD+ RS-422 Receive Input + Input 8 RS-422 RXD- RS-422 Receive Input - Input 9 +5 Volt +5 Volt Power Output * Output


Table 3-19. RS-232 / RS-422 Port Mating Connector (J206) 9-Pin male D-style con. Aerotech Third Party Source Connector ECK00137 Cinch DE-9P Back shell ECK01021 Amphenol 17-1724-2



Figure 3-11. RS-232/RS-422 Connector (J206)



3.5. FireWire Bus (J201, J202, J203)

The FireWire bus is the high-speed communications media to the Ndrive HL, operating at 400 megabits per second. All command and configuration information is sent via the FireWire. All three ports are effectively in parallel, allowing any port to be used when daisy-chaining the Ndrive HLs together or with other devices such as the Ndrive CP, HP, Nstep, Nservo or Npaq. The FireWire bus power is independent of the Ndrive HL power. Should a drive fail, communication will be maintained with the other devices.

Table 3-20. J201, J202, J203 FireWire Connector Pin Assignment Pin # Label Description In/Out/Bi. 1 Bus Power FireWire Adapter Power In/Out

2 Physical Ground FireWire Common (Isolated from Signal Common) N/A

3 * TPB# Port # Communication Signal Bi-directional 4 * TPB# + Port # Communication Signal Bi-directional 5 * TPA# Port # Communication Signal Bi-directional 6 * TPA# + Port # Communication Signal Bi-directional 7 Frame Chassis Frame N/A 8 Frame Chassis Frame N/A 9 Frame Chassis Frame N/A

* Port 0, 1, and 2, respectively, as represented in the table by a # .

Pin 1 of the FireWire connectors J201-J203, the power pin, are protected by a re-settable semiconductor fuse. If an over-current condition occurs, the device will open to protect against the overload. To reset the over-current device, remove the overload condition.



3.6. Voltage-to-Current Mode Operation

The firmware (version 2.06 and later) on the Ndrive HL supports a voltage-to-current mode. This mode allows the unit to run in a standalone mode, attached to a master position/velocity loop controller.

The standard operating mode of the Ndrive HL uses an OHCI IEEE-1394 connection from a host PC running the Nmotion SMC (software motion controller) to control servos. This connection is required for proper operation in this mode, since the fire wire connection provides positioning and synchronization information to the drive.

Figure 3-12. Normal Operation

The Voltage-to-Current mode of the Ndrive HL allows for a connection to a host controller that outputs ±10V DC as a torque (current) command. In this mode, a connection to the fire wire is not required (synchronization is performed internally), except for parameter configuration.

Figure 3-13. Stand-Alone Configuration

This mode allows the drive to be used in a general-purpose current-control mode with older existing control hardware.



3.6.1. Parameter Setup and Hardware Configuration Setup for the Voltage-to-Current mode should be performed using the Automation 3200 SMC. This software interface should be used to configure the parameters on the drive. The parameters of principal concern are:

! Current Loop Parameters (gains, offsets, etc.)

! Feedback configurations (feedback types, channels, etc.)

! Commutation Information (pole pairs, counts per cycle, etc)

! Current Clamp/RMS Current Trap

These are the parameters that will need to be saved to the flash memory within the Ndrive HL, before the standalone mode is activated. To enter the normal, A3200 operating mode, power down the drive and set DIP switches #6 and #7 to the ON position.

Once the parameters are correctly configured to run the motor with the A3200 (and verified) they can then be saved to the flash memory.

This initial setup should only need to be performed once for a given system type. If the parameter settings for a given axis in the system have already been verified, then on all future systems the A3200 software can be used to load the parameters for that axis into the Ndrive HL/HP so that they can be saved to the flash memory on that drive. Re-configuration should only need to be done for a different system, or if it is expected that some other system parameter may have changed.

3.6.2. Saving Parameters to the Flash Memory on the Drive Open the Ndebug.exe utility and select the axis (by typing AX n, where n is the 1-based axis number, of the axis you wish to select). Save the parameters to flash memory by typing:

FLASHWRITE 1 0 0

This will save the current system configuration into the flash memory on the Ndrive HL.

To enter the voltage-to-current mode, power down the Ndrive and set DIP switches #6 and #7 to the OFF position. When the unit is powered on again, it will auto-boot into the voltage-to-current mode.



3.6.3. Operation In the Voltage-to-Current mode, the Ndrive HL acts as a simple voltage-to-current controller. Analog Input 0 provides the current/torque command. Analog input 0 is accessible through either the -IOPSO option board or the J205 connector.

To emulate a standalone drive, the Ndrive HL also uses Input #8 (least-significant input bit on the J205 connector) as a drive enable input, and Output #8 (least-significant output bit on the J205 connector) as a fault output indicator. These I/O points utilize a default polarity that makes them fail-safe. Both are optically isolated. See Figure 3-2 and Figure 3-3 for I/O connection information. Also, note that the fault output requires a pull-up resistor to an external power supply.

The analog input is configured to accept input voltages from 10V to +10V. In this mode, +10V is equivalent to peak amplifier current command in the negative (CCW) direction, while 10V is equivalent to peak amplifier current command in the positive (CW) direction. The drives peak current is defined by the drive part number (i.e. Ndrive HL 20 indicates that the peak output current will be 20 amps.)

The analog input is differential, utilizing pins J205-13 (Analog input 0+) and J205-14 (Analog input 0-). See Figure 4-9 for more information.

The diagrams above indicate that current flow through pins 17 and 24 will enable the axis to drive current through the motor (failsafe; by default, no motor current will be present). Also, they indicate that a fault condition will be indicated by no current flow from pin 7 to pin 15 through the fault output (failsafe; by default, no current flow indicates a drive fault. When the drive is powered up and no fault condition exists, the opto-isolator will conduct current).

3.6.4. Faults A Drive Fault in the standalone mode can be caused by any of the following issues:

! Drive Over-Current (Peak current commanded for 1 second)

! Motor Over-Current (RMS threshold)

! Thermistor Over-Temperature Fault (Motor)

! Amplifier Temperature Fault

! Loss of Bus Power

∇ ∇ ∇

Ndrive HL Users Manual Options


CHAPTER 4: OPTIONS

4.1. IOPSO and IOPSOH Option Boards

See the following sections for details on the connector pin assignment and technical information for the IOPSO and IOPSOH options.

Figure 4-1. IOPSO Option Board Location

The IOPSO expansion board has 8 opto-isolated inputs (sinking or sourcing) and 8 outputs (sinking or sourcing), two 18-bit analog outputs, two 16-bit differential analog inputs, SSI Net, absolute encoder interface and brake relay, and includes HCPL2601 opto-isolator.

TB302J301 J302

JP3

J303

TB301

JP2

TB305

JP1

TB303 TB304

Figure 4-2. IOPSO Option Board (690D1579 Rev. A)

Table 4-1. IOPSO Option Board Jumpers Jumper Setting Description

1-2, 3-4* Brake Option at J207 JP1

1-3 Auxiliary relay Output Option at TB301 (Remove 1-2, 3-4 and 2-4) 1-2* Input 0 at TB305-3 is input 0

JP2 2-3 Input 0 at TB305-3 drives the external Reset Input 1-2 PSO (Laser Firing) Output is Active High

JP3 2-3* PSO (Laser Firing) Output is Active Low

*factory default setting

Options Ndrive HL Users Manual


The -IOPSOH expansion board has 8 opto-isolated inputs (sinking or sourcing) and 8 outputs (sinking or sourcing ) rated at 1 A per channel, two 18-bit analog outputs, two 16-bit differential analog inputs, SSI Net, absolute encoder interface and brake relay, and includes HCPL2601 opto-isolator.

BOTTOM VIEW

TOP VIEW

Figure 4-3. IOPSOH Option Board (690D1623 Rev. 0)

Table 4-2. IOPSOH Output Device Numbers Output Designator Description Aerotech P.N. 3rd Party P.N.

M49 Sourcing Driver ECS01079 NEC PS710E-1A Bit 0

M58 Sinking Driver ECS01079 NEC PS710E-1A M43 Sourcing Driver ECS01079 NEC PS710E-1A

Bit 1 M59 Sinking Driver ECS01079 NEC PS710E-1A M37 Sourcing Driver ECS01079 NEC PS710E-1A






Bit 7 M65 Sinking Driver ECS01079 NEC PS710E-1A

4.1.1. Brake Configuration Jumpers Setting JP1 to 1-2, 3-4 allows connection of the brake relay to pins 13 and 25 of the motor feedback connector (J207). See Figure 4-5 in section 4.1.3 for more information.



4.1.2. Analog Outputs (TB301) Both analog outputs are driven by an 18-bit AD1868 digital to analog converter and buffered by TL084 op-amps, producing a single-ended output voltage in the range of ±10 volts. This produces a resolution of 76.3 uVolts per bit of the D/A. The output current is limited to less than 50 mA. Note that the analog outputs are referenced to TB302-1 (as shown in Figure 4-4). Analog output 0 is also available at J205 (see Section 3.1.2). The analog outputs will be zero volts during reset.

Table 4-3. Analog Output Connector Pin Assignment (TB301) Pin # Label Description In/Out/Bi. 1 Analog 0 Out Analog Output 0 Output 2 Analog 1 Out Analog Output 1 Output

The analog output common may be found at J205 pin 23 or TB302 pin 1.

Figure 4-4. Analog Output Connector (TB301)



4.1.3. Brake / Relay (TB301) The relay output is typically used to automatically drive a fail-safe brake on a vertical axis, however, it may also be used as a general purpose relay. See the BrakeOnDriveDisable axis parameter for information on activating the brake output automatically, or the BRAKE command for manually toggling the output, both in the Nview HMI help. In order to help the user to interface to the brake relay the remainder of this section will be presented as a step-by-step procedure.

Step #1 Brake Relay Specifications

The user must verify that the application will be within the specifications of the Brake Relay contacts. These specifications are provided below in Table 4-4.

Table 4-4. Voltage and Current Specifications (TB301) Relay K1 Contact Ratings Maximum Switched Voltage 150 VDC, 125 VAC Maximum Switched Current 1A Maximum Carrying Current 1A Maximum Switched Power 30W (DC), 60 VA (AC) Note: The maximum power that may be switched is voltage dependent. Initial Contact Resistance 50 milliohms max. @ 10 mA, 6 VDC

The user must not exceed the maximum Current or maximum Power specifications.

Step #2 Select Brake Interface Connector

The Normally-Open (N.O.) contacts of the Brake Relay are accessible through TB301 and the Motor Feedback connector (J207). The Normally-Closed contact of the Brake Relay is only accessible through TB301 (see Figure 4-5). The Motor Feedback connector (J207) allows the brake wires to be included in the motor feedback cable and eliminate the need for a separate brake cable. The Brake Relay connections to TB301 are listed in Table 4-5 and the Brake Relay connections to the Motor Feedback connector (J207) are listed in Table 4-6.



Table 4-5. Brake / Relay Connector Pin Assignment (TB301) Pin # Label Description In/Out/Bi.

3 Relay-N.C. (Brake) Relay Output Normally Closed Contact Output 4 Relay-Com. (Brake) Relay Output Common Contact Output

5 Relay-N.O. (Brake) Relay Output Normally Open Contact (See JP1-A, JP1-B) Output

Table 4-6. Brake / Relay Connector Pin Assignment (J207) Pin # Label Description In/Out/Bi.

13 Brake - (Brake-) Relay Output Normally Open Contact (See JP1-A, JP1-B) Output

25 Brake + (Brake+) Power connection (See JP1-A, JP1-B) Output

Figure 4-5 is an example of a 24 VDC Brake connected to TB301. In this example, JP1-A and JP1-B must be configured. If JP1-A and JP1-B are configured to 1-3 then J207 pins 13 and 25 will be unused. If JP1-A is set 1-2 and JP1-B is set 3-4, a connection between pins 13 and 25 of J207 is required. In this case, J207 functions as an interlock to prevent the Brake from releasing if the Motor Feedback connector is not connected.

Figure 4-5. Brake Connected to TB301

The user may reconfigure the connections for the brake, such that the positive supply lead is switched by the relay instead of the supply common.



Figure 4-6 is an example of a 24 VDC Brake connected to the Motor Feedback connector (J207) In this example the external 24 VDC power source is connected to TB301. Also note that JP1-A is set 1-2 and JP1-B is set 3-4.

Figure 4-6. Brake Connected to J207

The user is responsible for providing fuse protection for the Brake circuit.




Step #3 Suppression and Snubber Requirements

Due to the inductive effects of the brake, suppression and/or snubber, components are needed to reduce arching and prevent damage to the Brake Relay contacts. Suppression can also reduce the electrical noise that is emitted when the circuit is switched off. Following are three suppression circuit examples.

Example #1: Figure 4-5 is an example of a typical 24 VDC brake circuit. In this example, the Varistor, is the suppression device, connected across the brake. This method of suppression is used in circuits operating at voltages up to 25 VDC and AC circuits operating at voltages up to 18 VAC. If the voltage is greater than 25 VDC or 18 VAC, one of the other suppression methods should be used.

Example #2: Figure 4-7 is an example of a suppression circuit that can be used for systems using a DC supply. In this example, the diode is the suppression component, which is connected across the brake. It is important that the diode be installed, so that it is normally reversed biased. This diode must have a reverse voltage rating greater than the users DC power supply and a maximum current rating of at least 1 Ampere. Due to the time needed for this suppression device to dissipate the energy released by the load inductance there may be a slight delay (less than 1 second) before the brake responds to its power being switched off. If this delay is unacceptable, Example #3 should be used.

Figure 4-7. Diode Suppression for DC Brake Systems




Example #3: Figure 4-8 is a suppression circuit that can be used for both AC and DC circuits. In this method, a resistor, capacitor and a varistor are used across the load (see Figure 4-8). In some cases, better results are obtained by installing the suppression devices across the relay contacts. The ratings and values for these components are described below.

Resistor (R): calculated by the following formula, Power rating = ½ Watt.

Resistor (ohms) = Voltage / Load current If the Resistor is less than 24 ohms use 24 ohm resistor. If the Resistor is greater than 240 ohms use 240 ohm resistor. If the resistance of the Resistor is too low the relay contacts may fuse

together. If the resistance of the Resistor is too high, the contacts may be damaged

due to excessive arching. Capacitor (C): .1 uF, rated for AC circuits and a voltage rating of not

less than 250 Volts. If the voltage rating of the capacitor is too low, the Varistor may not be able to protect it and it may fail.

Varistor (V): Rated for the maximum voltage of the users power

supply, Typically, a varistor rated for a standard 120 VAC line should work well. Verify that the capacitor voltage rating is greater than the clamp voltage of the varistor. If the voltage rating of the varistor is too low, it may conduct during normal operation and overheat. If the voltage rating of the varistor is too high, it may not protect the capacitor (C) against over-voltage conditions.

Figure 4-8. RC Suppression for DC Brake Systems


Ndrive HL User’s Manual Options


4.1.4. Analog Inputs (TB302)

Both analog inputs are differential, buffered by a precision unity gain differential INA105 amplifier and converted to digital by a 16-bit ADS8320 analog to digital converter allowing an input voltage in the range of ±10 volts. This produces a resolution of 305 uVolts per bit of the A/D.

Analog input 0 is also available at J205, see Section 3.1.3. The analog inputs have a 25k Ohm input, impedance and should be driven by a low impedance source such as an op-amp output.

To interface to a single-ended (non-differential) voltage, refer to Figure 4-9; connect the signal common of the source to the negative (-) input and connect your signal to the positive (+) input. A floating signal source should be referenced to the signal common (pin 1, AGND) as shown in Figure 4-9.

Table 4-7: Optional Analog Input Connector Pin Assignment (TB302)

Pin # Label Description In/Out/Bi. 1 Analog Ground Analog Common N/A 2 Analog0 In + Non-Inverting Analog Input 0 Input 3 Analog0 In - Inverting Analog Input 0 Input 4 Analog1 In + Non-Inverting Analog Input 1 Input 5 Analog1 In - Inverting Analog Input 1 Input

Figure 4-9: Optional Analog Input Connector (TB302)

See text above



4.1.5. User Power Connector (TB303) This connector provides access to the Ndrive HLs internal power supply, which may be used to power external devices (500 mAmps maximum). It also provides a connection to power the opto-isolated PSO output (see Section 4.1.8., Figure 4-15).

Table 4-8. User Power Connector Pin Assignment (TB303) Pin # Label Description In/Out/Bi 1 +5 User Return User +5 Volt Signal Common N/A 2 +5 User Return User +5 Volt Signal Common N/A 3 +5 Ext. User +5 Volt Power * Output 4 FP Power for PSO opto-isolated output Input 5 FM Common for PSO opto-isolated output N/A

* Total user +5V power from all outputs is limited to 500mA, by an internal re-settable fuse.

4.1.6. Opto-Isolated Outputs (TB304) The outputs are software configurable via the DriveIOConfig axis parameter as sourcing or sinking, and are driven by a PS2802-4 opto-isolator that is rated for 40 volts DC maximum and up to 80 mA/channel, not to exceed 90 mW per channel. Figure 4-10 and Figure 4-11 illustrate how to connect to the output in current sinking and current sourcing modes, respectively.

The connection must always be made to both the Output Common Plus and Output Common Minus connections to prevent glitches on the outputs, as shown in the wiring diagrams in Figure 4-10 and Figure 4-11.

Table 4-9. Opto-Isolated Output Connector Pin Assignment (TB304) Pin # Label Description In/Out/Bi 1 OP Output Common Plus Input 2 OM Output Common Minus Input 3 Output 0 Output 0 (optically isolated) Output 4 Output 1 Output 1 (optically isolated) Output 5 Output 2 Output 2 (optically isolated) Output 6 Output 3 Output 3 (optically isolated) Output 7 Output 4 Output 4 (optically isolated) Output 8 Output 5 Output 5 (optically isolated) Output 9 Output 6 Output 6 (optically isolated) Output 10 Output 7 Output 7 (optically isolated) Output



Table 4-10. Output Specifications (TB304) Specification -IOPSO Value -IOPSOH Value Maximum Power Dissipation 90 mWatts / Channel 600 mWatts / Channel Maximum Voltage 40 Volt Maximum 24 Volt Maximum Maximum Sink/Source Current 80 mAmps / Channel 1 Amperes / Channel Output Saturation Voltage ~ 0.7 0.9 Volts ~ 0.32 Volts Rise / Fall Time 250 usec (typical) 1 msec (typical) Maximum Output Frequency 1 kHz 100 Hz

Figure 4-10. Connecting Outputs in Current Sinking Mode

Figure 4-11. Connecting Outputs in Current Sourcing Mode



Suppression diodes must be installed on outputs that are used to drive relays or other inductive devices to protect the output devices from being damaged by the inductive spikes that occur when the device is turned off. Suppressor diodes can be installed on all outputs to provide greater protection. The 1N914 diode is recommended for this application. It is important that the diode be installed correctly (normally reversed biased). See Figure 4-10 for an example of a current sinking output with diode suppression and Figure 4-11 for an example of a current sourcing output with diode suppression.

4.1.7. Opto-Isolated Inputs (TB305) The inputs are configured for 5-24 volts DC logic, using a higher input voltage, requires adding external series resistors to limit the current. The opto-isolator is a PS2806-4 device. The inputs may be connected to current sourcing or current sinking devices, as shown in Figure 4-12 and Figure 4-13. Each 4-bit bank of inputs (0-3 or 4-7) must be connected to either all current sourcing or all current sinking devices. Also, note in the table below, that inputs 0-3 and inputs 4-7 have two different common inputs, pin 1 and pin 2, respectively. See Section 3.3.1 for opto-isolated EOT limit inputs.

Table 4-11. Opto-Isolated Input Connector Pin Assignment (TB305) Pin # Label Description In/Out/Bi 1 C0-3 Input Common for inputs 0 - 3 Input 2 C4-7 Input Common for inputs 4 - 7 Input 3 Input 0 Input 0 (Optically-Isolated) See pin 1 Input 4 Input 1 Input 1 (Optically-Isolated) See pin 1 Input 5 Input 2 Input 2 (Optically-Isolated) See pin 1 Input 6 Input 3 Input 3 (Optically-Isolated) See pin 1 Input 7 Input 4 Input 4 (Optically-Isolated) See pin 2 Input 8 Input 5 Input 5 (Optically-Isolated) See pin 2 Input 9 Input 6 Input 6 (Optically-Isolated) See pin 2 Input 10 Input 7 Input 7 (Optically-Isolated) See pin 2 Input



Figure 4-12. Inputs Connected in Current Sourcing Mode

Figure 4-13. Inputs Connected in Current Sinking Mode



4.1.8. PSO / Absolute Encoder Interface (J301) This connector utilizes the RS-485 port and the (analog sine wave) encoder channel as an absolute encoder interface. The absolute encoder channel accepts a differential analog encoder up to 200 kHz. Typically, this is a 1 Volt P-P signal varying about a 2.5 Volt reference. See Figure 2-5, Figure 2-6, Figure 2-7, and Figure 2-11 in Section 2.4. for connection information. The two RS-422 channels provide buffered and/or multiplied MXH encoder signals to the user, for laser firing or other purposes. Additionally, the IOPSO option provides a RS-422 output and an open-collector laser-firing signal to the user. Only one of these signals may be used, as illustrated in Figure 4-15. Jumper JP3 defines the active state of the open-collector output, which has three options, as defined in Table 4-12. See Section 4.2. for more information on the laser firing (PSO) option. Note that the two RS-422 channels are two of the same channels available on the J302 and J303 connectors. For information on the RS-422 ports, see Figure 4-17 in Section 4.1.9.

See Figure 4-15 for the firing output.

Table 4-12. PSO/Absolute Encoder Interface Connector Pin Assignment (J301) Pin # Label Description In/Out/Bi 1 Chassis Frame Ground Chassis Frame Ground N/A 2 Sin-N SSI Net #1 Sin-N Bi-directional 3 Sin SSI Net #1 Sin Bi-directional 4 Cosine-N SSI Net #1 Cosine-N / Marker-N Bi-directional 5 Cosine SSI Net #1 Cosine / Marker Bi-directional 6 Common (+5 Volt External) Common N/A 7 Absolute Sine + Input Absolute Encoder Interface Input 8 Absolute Sine - Input Absolute Encoder Interface Input 9 Absolute Cosine + Input Absolute Encoder Interface Input 10 Absolute Cosine Input Absolute Encoder Interface Input 11 PSO-IOC/RS-422-M Output PSO / RS-422 - Output * Output 12 RS-422-P Output RS-422 + Output 13 +5 Volt External See Pin 6 External +5 Volt supply Output 14 RS-485-M RS-485 for Abs. Encoder Bi-directional 15 RS-485-P RS-485 + for Abs. Encoder Bi-directional

* Users should use the opto-isolated output where possible to maintain the isolation between the Ndrive HL and the laser. This prevents noise and current spikes (from laser firing pulses) from being conducted through the Ndrive HL! This requires the user to power the opto-isolator at TB303 (see Section 4.1.5. for more information).

Table 4-13. PSO / Absolute Encoder Mating Connector (J301) 15-Pin D-Style Aerotech Third Party Source Connector ECK00100 Keltron P/N DN-15PYSH-G Back shell ECK01022 Amphenol P/N 17-1725-2



Table 4-14. Laser Output Opto-Isolator Specifications

M12 Device (Option#) (Figure 4-15)

Nominal Frequency

Propagation Delay (Typ.)

Power Supply Voltage

Output Current Sink

*HCPL-2601 (PSOOPTO1 option, std) 5 MHz .05 us. 5 VDC 10 mA

6N136 (PSOOPTO2 option) 750 KHz .45 us. 5-15 VDC 2 mA

4N33 (PSOOPTO3 option) 10 KHz 3 us. 5-25 VDC 50 mA

TIL117-M (-PSOOPTO4 option)

40 KHz 2 us.

5-25 VDC 50 mA

Figure 4-14. Absolute Encoder Interface (J301)



Figure 4-15. PSO Interface (J301 and TB303)

Output 11 and the Auxiliary Marker on J205 (pins 19 and 20) may also be defined as the PSO Laser Firing output via the PSOCONTROL command. See Section 3.2 for connection and other information.

Figure 4-16. (RS-485) Absolute Encoder Interface (J301)



4.1.9. SSI Net (2 channel) (J302, J303) Each of the two SSI Net interfaces is a two-channel bidirectional RS-422 interface, most typically for quadrature encoders. This allows one channel for the sine signal and one channel for the cosine signal. Alternatively, one of the SSI Net interfaces may be used to provide an encoder marker signal to another SSI Net interface if used. Each of these two SSI Net interfaces are both available on the J302 and J303 connectors, as illustrated in the following table. Note that the J205 encoder channel may also be used as an input/output for multi-axis PSO firing.

The SSI Net is designed for daisy-chaining encoder signals from one Ndrive HL to another for two/three-axis PSO (laser firing). This allows one Ndrive HL containing the DUALPSO or TRIPLEPSO options to track the vectorial position change of two/three axes in real-time. These encoder signals may also be used for user-defined purposes. Refer to Figure 4-17 and Figure 4-18. These four channels are bi-directional and configured via the PsoSsiConfig and PsoSsi2Config axis parameters; see the Nview help for more information. Note that SSI Net #1 is also available on the J301 connector (see Section 4.1.8.). The signals from these ports will be the same as the differential line driver encoder signal input to the Ndrive HL, unless the MXH option is present. The signal output, when the MXH option is present, will be of a pulse width determined by the MXH clock frequency, as indicated in Table 3-17.

SSI Net #1 and #2 interfaces are both physically hardwired to the J302 AND J303 connectors. If SSI Net #1 is configured as an input, a signal driven into the SSI Net #1 connections on J302, will also be present on the SSI Net #1 connections of J303, effectively making SSI Net #1 on J303 an (un-buffered) output of this same signal. Likewise, this would also be true for the SSI Net #2 interface.

Table 4-15. J302, J303 2-Channel SSI Net Connector Pin Assignment Pin # Label Description In/Out/Bidirectional 1 Sin-N SSI Net #1 Sin-N Bidirectional 2 Sin SSI Net #1 Sin Bidirectional 3 Cosine-N SSI Net #2 Cosine-N / Marker-N Bidirectional 4 Sin-N SSI Net #2 Sin-N Bidirectional 5 Sin SSI Net #2 Sin Bidirectional 6 Cosine SSI Net #2 Cosine / Marker Bidirectional 7 Cosine-N SSI Net #1 Cosine-N / Marker-N Bidirectional 8 Cosine SSI Net #1 Cosine / Marker Bidirectional



Figure 4-17. J301/J302/J303



4.2. DUALPSO and TRIPLEPSO Laser Firing Options

The Ndrive HL allows two and three-axis laser firing with its DUALPSO and TRIPLEPSO options. To accomplish this, the encoder signals from a second/third Ndrive HL must be connected (or daisy-chained) from that Ndrive HL to the Ndrive HL with the DUALPSO or TRIPLEPSO options. This requires an encoder signal from another axis via the J205 connector (Section 3.2) or via one of the J302, J303 SSI Net connectors. If the J205 connector is used, it must be configured as an output via the EncoderDivider axis parameter. If the SSI Net is used it requires a cable (see Table 4-16 and Figure 4-18) from J302 to J302 of each Ndrive HL (J302 to J302 or J303 to J303 of the other Ndrive HL, both connectors each have the same two SSI Net ports present on each connector. The ports on each drive must then be configured via their PsoSsi1Config/PsoSsi2Config (or PsoMrk1Config/PsoMrk2Config) axis parameters, out and in, respectively, so the encoder signals are supplied to the Ndrive HL with the DUALPSO or TRIPLEPSO options. Additionally, the CfgEncMxhSetup axis parameter must be configured for a 20 MHz. clock or less, so as not to exceed the 31 nsec. minimum edge separation specification. Also, the PSO pre-scalars may be required to limit each encoder being tracked to a 5 MHz. data rate (which does not affect the servo feedback loop data rate). The figure below shows two and three-axis firing, which are very similar. See the Nview HMI help for more information on parameter configurations.

Note that the J205 encoder channel may be configured as an output via the EncoderDivider axis parameter, allowing other multi-axis PSO firing configurations.

Figure 4-18. Two / Three Axis Laser Firing Interconnection



Table 4-16. SSI Net Cable Part Numbers

Part # Description NConnect-SSINet-4500 4.5 M (15 FT) SSI Net Cable NConnect-SSINet-3000 3.0 M (10 FT) SSI Net Cable NConnect-SSINet-1500 1.5 M (5 FT) SSI Net Cable NConnect-SSINet-900 0.9 M (3 FT) SSI Net Cable

4.2.1. PSO Tracking Rate Configuration

The following only applies to Ndrive HLs with the DUALPSO or TRIPLEPSO options and the MXH option, with high encoder data rates.

The maximum clock frequency of the MXH multiplier should be limited to 20 MHz. when using the DUALPSO or TRIPLEPSO options. This is due to a maximum encoder date rate of approximately 32 MHz. on the Ndrive HLs encoder input ports. The 20 MHz. clock rate is achieved by setting the Clock Select 1 field of the CfgFbkEncMxhSetup axis parameter (value of 0x1 as shown below). This must be done when using DUALPSO or TRIPLEPSO options in order to ensure that encoder count information is not lost.

The 20 MHz. data rate limitation effectively limits the maximum speed of the axis (see B below). In addition, the DUALPSO or TRIPLEPSO options have a maximum tracking rate of 5 MHz. due to hardware limitations. The PSO data rate can be reduced to 5 MHz. while allowing the servo loop to operate at 20 MHz. by using the following PSOTRACK <axis> SCALE 4 4 4 command. This command divides the encoder signals before the PSO counters by a factor of 4 and therefore limits the frequency seen by the PSO tracking counters to 5 MHz. However, the servo loop is still able to run at the full 20 MHz. rate.

The effective PSO programming resolution is now 1/4 that of the servo loop (full) resolution. PSODISTANCE commands should be entered 4 times lower than the full resolution in this case.

Figure 4-19. PSO Tracking Rate Block Diagram



EXAMPLE:

It is desired to generate a pulse output every 1,000 encoder counts in DUALPSO or TRIPLEPSO mode. The individual axis speeds approach 20 MHz. during the motion and therefore exceed the 5 MHz. DUALPSO or TRIPLEPSO tracking limitation. The PSOTRACK <axis> SCALE 4 4 command must be used and the PSODISTANCE values reduced by a factor of 4 as follows PSODISTANCE X FIXED 250 STEPS ; distance specified with 1/4

; actual resolution

In order to run the servo loop at full encoder resolution and data rates above 20 MHz., Ndrive HL software versions 2.02 and above contain the CfgFbkEncMxhQuadDiv axis parameter which acts as an MXH output divider. This parameter allows you to specify a lower resolution for the MXH quadrature output signal only (used by DUALPSO or TRIPLEPSO options on other drives). The effective resolution is the full resolution, as derived using CfgFbkEncMultFactorMXH axis parameter, divided by the CfgFbkEncMxhQuadDiv axis parameter.

The servo loop always runs at the full resolution as determined by the CfgFbkEncMultFactorMXH axis parameter. The CfgFbkEncMxhQuadDiv axis parameter does not affect servo loop resolution.

EXAMPLE:

An application uses a 4um linear encoder with an MXH option on an Ndrive HL. It is desired to move the motor at a maximum speed of 200mm/second and track using the DUALPSO or TRIPLEPSO option. CfgFbkEncMultFactorMXH = 500 ; value for 2nm servo loop

; resolution

Encoder resolution = 250 lines /mm * 500 * 4 = 500,000 counts / mm (2nm)

Encoder data rate at 200mm/sec = 500,000 * 200 = 100Mhz

This exceeds the DUALPSO or TRIPLEPSO maximum encoder tracking rate of 5 MHz. and must be reduced by 100/5 = 20. Set the CfgFbkEncMxhQuadDiv axis parameter to 20 to achieve this. The user must now program the PSODISTANCE command in units of 40 nm instead of 2 nm.



4.3. ENET (Ethernet) Option J204

The optional Ethernet port provides connectivity to a 10/100 Base-T ModBus TCP network, or the PCs Ethernet port may be used. This is typically used for adding analog and digital I/O to the controller. See the Ethernet I/O help on the Windows Start bar on the Automation 3200 menu. Additionally, the IOPSO option provides analog and digital inputs and outputs, see Section 4.1 for more information.

Table 4-17. Ethernet Connector Pin Assignment (J204) Pin # Label Description In/Out/Bi. 1 TX + Transmit Data + Output 2 TX - Transmit Data - Output 3 RX + Receive Data + Input 4 Unused RC Terminated N/A 5 Unused RC Terminated N/A 6 RX - Receive Data - Input 7 Unused RC Terminated N/A 8 Unused RC Terminated N/A

Figure 4-20. Ethernet Interface (J204)

Table 4-18. NConnect I/O Cable part Numbers Part Number Description NConnect-IO-900 Ethernet crossover cable 900mm (3 ft.) NConnect-IO-1500 Ethernet crossover cable 1500mm (5 ft.) NConnect-IO-3000 Ethernet crossover cable 3000mm (10 ft.) NConnect-IO-4500 Ethernet crossover cable 4500mm (15 ft.)



4.4. RDP Resolver Input

The optional resolver input provides two industry standard resolver or Inductosyn channels, which may each be used as a feedback device. Each may be separately configured for resolver or inductosyn input, as shown in Table 4-21. The standard reference output frequency is 10 kHz, optionally it may be configured as 5 or 7.5 kHz at the factory.

The Sine and Cosine feedback signals should be adjusted for 2 volts RMS (2.8 volts Peak) via the CfgFbkRDGain axis parameter. The resolver can be physically aligned to the motor, by using the MSET CNC programming command. This physical relationship may also be defined via the CfgMotOffsetAng axis parameter. All of which is described in Section 4.4.1. See the Nview help for information on configuring the axis parameters for an axis with resolver feedback.

The J403 external power connector is not available at this time.

Table 4-19. Resolver Connector Pin Assignment (J1, J2) Pin # Label Description In/Out/Bidir. Shell Shield Connector shell for cable shield termination Input 1 Enc Cos + Optional Encoder Cosine + output Output 2 Enc Mrk + Optional Encoder Marker + output Output 3 Common Resolver Common input Input 4 Sin + Resolver Sine + input Input 5 Sin - Resolver Sine - input Input 6 Enc Cos - Optional Encoder Cosine - output Output 7 Enc Sin + Optional Encoder Sine + output Output 8 Reserved N.A. 9 Common Resolver Reference Common input Input 10 Reference Resolver Reference output Output 11 Enc Sin - Optional Encoder Sine - output Output 12 Enc Mrk - Optional Encoder Marker - output Output 13 Common Resolver Common input Input 14 Cos + Resolver Cosine + input Input 15 Cos - Resolver Cosine - input Input

The following mating connector is always provided with the resolver option, which may be ordered separately as part number, MCK-15HDD.

Table 4-20. Resolver Mating Connector (15-Pin Male D-Style) Aerotech Third Party Source Connector ECK01287 Amphenol 17HD-015P-AA000 Back shell ECK01021 Amphenol 17-1724-2

Table 4-21. Resolver Jumper Configuration

Axis/JP # Resolver Inductosyn JP1 1-2 (Channel 1) - Default 2-3 (Channel 1) JP2 1-2 (Channel 2) - Default 2-3 (Channel 2)



Table 4-22. Resolver Test Points

Test Point Number Description TP4 Signal Common TP10 Sine input Channel 1 TP11 Cosine input Channel 1 TP12 Reference signal Channel 1 TP20 Sine input Channel 2 TP21 Cosine input Channel 2 TP22 Reference signal Channel 2

Figure 4-21. Resolver Option Assembly (690D1599 Rev. 0)

Table 4-23. External Power Pin Assignment (J403) Pin # Label Description In/Out 1 +12 VDC +12 Volts DC Input 2 -12 VDC -2 Volts DC Input 3 Common Signal Common N.A

4.4.1. Resolver/Inductosyn Setup There are three fundamental steps of configuring the RDP option board:

• Configuring the Resolver Hardware

• Configuring the Resolvers Analog Feedback Signals

• Configuring the Commutation Parameters



4.4.1.1. Configuring the Hardware

There is a limited amount of hardware configuration capability on the RDP option board; most capability must be ordered as a factory option. These features include carrier frequency and the number of R/D converter channels, 1 or 2.

There are two jumpers located on the RDP board. These are used to select the reference signal for the converter chip (i.e. SIN vs. COS). Jumper JP1 selects the reference for channel 1 and jumper JP2 selects the reference for channel 2.

NOTE: Typically these jumpers only require being changed when inductosyns are used.

The SIN reference is a fixed-phase signal, which is in phase with the reference signal used by the resolver. The COS reference is a variable-phase signal which may be phased shifted with respect to the reference of the resolver/inductosyn to optimize the alignment of the feedback (required for inductosyns, which nominally provide a 90 degree phase shift on feedback; optional for resolvers with significant phase loss). The default phase offset is 90 degrees. For most inductosyns, this value will need to be varied from system to system to optimize performance. See Figure 4-22 below for example phasing.

Some Aerotech systems may have an optional pre-amplifier board. This may be installed within the mechanics itself, as is the case with an Aerotech AOM360D optical mount. If so, the first step is to adjust the P1 potentiometer on the pre-amplifier board to equalize the Sine and Cosine feedback signals to the same amplitude.

Figure 4-22. Analog Output Connector (TB301)



4.4.1.2. Configuring the Analog Feedback Signals

Using the Encoder Feedback Configuration Utility to set up a resolver/inductosyn

The RDP option of the Ndrive HL can be optimally aligned quickly, using the Encoder Feedback Configuration utility within the NScope.exe utility.

When the Ndrive HL is configured for Resolver Feedback (via the CfgFbkPosType axis parameter), then the currently selected channel (1 or 2, defined via the CfgFbkPosChan axis parameter) of the RDP board will output its analog inputs for SIN/COS into the analog input channels of the Encoder Configuration Feedback utility (a utility also used to configure the -MXH option). The values sampled by the analog inputs reflect the peak value of the carrier-frequency sine waves used by the Resolver to Digital converter.

The Position feedback type, at present, dictates which analog channels are sampled.

There are two axis parameters, which are used to configure the analog feedback from a resolver or inductosyn for optimum performance:

• CfgFbkRDGain defines the peak amplitude of the reference sine wave to the resolver.

• CfgFbkRDCosPhase defines the phase delay on the Cosine phase of the dual-phase oscillator.

When to use the CfgFbkRDCosPhase axis Parameter:

The Cosine reference signal can be adjusted from approximately 0 degrees (i.e. in phase with the SINE reference signal) to 180 degrees, with a nominal value of 90 degrees. This axis parameter is primarily for use with inductosyns, which have a nominal phase shift from the reference signal of 90 degrees. This value may vary from system to system, and therefore can be adjusted to ensure that the alignment of the feedback signals to the reference signal is at its optimum, for better performance.

This signal can also be used to adjust for resolvers that have a large amount of phase lag. Typically, less than 5 degrees of phase lag is acceptable and does not require use of the COS reference.

Use of this axis parameter requires that the jumper on the RDP board for this channel (JP1 for channel 1 or JP2 for channel 2) be set from 2-3 instead of from 1-2. Also, in order for the A/Ds to sample properly, the appropriate bit in the CfgFbkRDConfig axis parameter should be set to 1 (bit 0 for channel 1 or bit 1 for channel 2).

For most resolvers, use of the CfgFbkRDCosPhase axis parameter is not required. If this axis parameter is not being used, the jumpers should be set to 1-2 and the bits in the CfgFbkRDConfig axis parameter should be set to 0. Skip to the section on adjusting the R/D Gain.



Adjusting the CfgFbkRDCosPhase axis Parameter:

After starting the Encoder Feedback Configuration utility, make sure the proper axis is selected and then start collecting data continuously. Set the CfgFbkRDGain axis parameter to 0 to minimize the gain. This can be done through the Ndebug.exe utility. Rotate the resolver or inductosyn until the analog signals are at one of the vertical or horizontal lines; this will ease location of a maximum. See Figure 4-23., below, for an example. Adjust the CfgFbkRDCosPhase axis parameter until you locate a local maximum. This can be done through the Ndebug.exe utility. When the maximum has been found, rotate the motor in a complete circle to ensure you see a circle. If not, the P1 amplitude potentiometer on the pre-amplifier board (if present), may need adjusted.

Figure 4-23. Resolver Located at Maximum of SIN Signal



Figure 4-24. Rotating the Resolver (to see a circle)

For this to function you MUST have the proper jumper set to 2-3 for this channel and the bit in the CfgFbkRDConfig axis parameter set to 1. Otherwise, erratic results may occur.

Adjusting the gain of the R/D converter

Once the phase is adjusted for optimum conversion for inductosyns, adjust the CfgFbkRDGain axis parameter until you see the analog signals peaking between approximately 5,000 (on the low end) and 60,500 (on the high end) counts. This axis parameter can be adjusted via the Ndebug.exe utility. These numbers equate to approximately 0.38 to 4.62 volts on a zero- to 5-volt scale, or ±8.48 volts on a ±10V scale (i.e. via the Nstat.exe utility), depending upon where you measure the signals. This nominally provides 2V RMS (2.83 volts peak) to the converter chip on the RDP option board, which is required for optimum operation. See Figure 4-25. for an example of an optimum circle.



Figure 4-25. Optimized Resolver Feedback Configuration

4.4.1.3. Configuring the Commutation Initialization

The commutation of brushless motors with resolver feedback may be initialized two ways. The first method uses the number of motor pole pairs combined with the maximum resolution of the R/D board to determine an initial commutation position. The second method initializes the motor normally using the Hall effect feedback signals.

Setting the CfgMotType axis parameter to Auto-MSET can be used if the R/D Auto-configuration or Hall effect signals cannot be used.

R/D auto-configuration typically CANNOT be used with inductosyns because they have multiple electrical cycles per revolution of the motor. R/D Auto-configuration will ONLY work if you have EXACTLY one cycle of the Sine and Cosine signals per revolution of the motor.



The Commutation Initialization method of the R/D is specified through bit 8 of the CfgFbkRDConfig axis parameter.

Setting this bit to 1, utilizes Hall-Effect commutation initialization (i.e. commutation is initialized similar to encoder feedback). Note that this requires proper hall-effect to back-EMF configuration and/or proper commutation phase shift axis parameter setting; see brushless motor setup information for more details.

Setting this bit to 0 uses the R/D Auto-Configuration, when the axis is enabled.

The Position feedback type at present dictates which channel is used for commutation initialization. Typical configuration of the R/D has the CfgFbkPosType axis parameter set to 6 and CfgFbkVelType axis parameter set to 0 (use position). If two resolvers or inductosyns are used in dual-loop mode, the position source will generate the commutation initialization but the velocity source will maintain commutation position after enable. Dual-Loop with resolvers and other feedback sources is not advisable.

Finding the Proper Commutation Offset in R/D Auto-Configuration Mode

The R/D Auto-Configuration mode assumes that the zero crossing of the R/D Converter is aligned with the 0 angle of commutation on the Ndrive HL. Therefore, to determine the commutation offset angle, perform the following steps:

The resolver absolute counter may also be read in the Ndebug utility via the command sequence: DSPMEMREAD 2 0xEB0006 for channel 1, or 0xEB0007 for channel 2.

1) Open the Nstat.exe utility.

2) Select the tab, which displays the absolute resolver feedback register.

3) Rotate the resolver until you have an approximate zero value on the feedback register (note that this value will roll over at 65535).

4) Begin with an MSET value of 0 degrees, execute MSET commands with an increasing angle until you see a value of 0 indicated for the absolute resolver angle. This MSET angle is the desired commutation offset.

5) Enter the value from step 4 into the CfgMotOffsetAng axis parameter. Note that for negative values, you must add 360 degrees (valid parameter range is 0-360 degrees).

∇ ∇ ∇

Ndrive HL Users Manual Accessories


CHAPTER 5: ACCESSORIES

5.1. Standard Interconnection Cables

The following three Tables show a summary of the standard cables used for interconnecting various items to the Ndrive HL.

To identify your cable or for a wiring/assembly drawing, see your software CD ROM.

Table 5-1. Standard Interconnection Cables Cable Part # Description C13803-xx DC Brush Motor Cable (DC MTR & FB-25DU FL-24MS-MAX107DM) C15291-xx Encoder Feedback Cable (BL FB-25DU-17MS 9DU-MAX120DM) C15805-xx Motor Cable (BL MTR FL 4MS) C1650X Encoder Feedback Cable (BL FB-25DU-25DU-MAX120DM) C1839X Encoder Feedback Cable (BL FB-25DU-25DU 9DU-MAX120DM)

C18982 Motor and Encoder Feedback Cable (BL MTR&FB-FL-25DU-25DU-107DM MAX)

C19360-xx Motor Cable (BL MTR-FL-4DU-MAX450DM) C19791 Joystick Extension Cable with Flying Leads (JSXT-FLY-XX) C19792 Joystick Extension Cable with D Style Connectors (JSXT-26HD-XX) C19793 Two-Axis Joystick Adapter Cable (J205 on two Ndrive HLs)

C19794 Two-Axis Joystick Adapter Cable with Flying Leads (J205 and IO option)

C19851 Hi-Flex Motor Cable (BL MTR-FL-4DU-HF-46DM) C19891-xx Auxiliary I/O to SSI Net 1 Cable C19892-xx Auxiliary I/O to SSI Net 2 Cable C20251-xx Stepper Motor Cable ECZ01231 BBA32 Interconnect Cable

xx = Length in decimeters

yy = Length in feet

Accessories Ndrive HL Users Manual


Table 5-2. Combined Motor & Feedback Cables Ndrive HL Part Number (s) Description Stage/Motor

C18982-xx BFMCDNT-yy

BL MTR & FB-25DU FL-25DU-MAX107DM Obsolete

Motor Output

Motor Feedback

Used On: Any brushless motor stage having a single 25 pin D style connector for motor power, encoder, limits and halls. ABL1000 series ALS130 & ALS135 series (Single connector version) ANT series, AVL125, & ADR175 ASR1000, 1100, & 2000 series (with 25D option)

Motor/Encoder / Limits / Halls

C13803-xx DC MTR & FB-25DU FL-24MS-MAX107DM

Motor Output

Motor Feedback

Used On: Any stage having a DC brush motor with a single 24 pin MS style connector for motor power, encoder, limits and brake.

Motor/Encoder / Limits / Brake

C20251-xx SM MTR & FB-25DU FL-23B-MAX107DM

Motor Output

Motor Feedback

Used On: Any stage having a stepper motor with a single 23 pin Burndy style connector for motor power, encoder, limits and brake.

Motor/Encoder / Limits / Brake


yy = Length in feet



Table 5-3. Individual Motor Cables Ndrive HL Part Number (s) Description Stage/Motor

C15805-xx PMCNT-yy

BL MTR-FL-4MS-MAX450DM Obsolete

Motor Output

Used On: Any brushless motor stage having a 4 pin MSstyle connector for motor power. BM/BMS motors (with -MS option) BMxxxE motors

Motor

C19360-xx PMCHPDNT-yy

BL MTR-FL-4DU-MAX450DM Obsolete

Motor Output

Used On: Any brushless motor stage having a 4 pin D style connector for motor power. BM/BMS motors (with -D25 option) ABL2000 & 8000 series ABR1000 Series ADR160 - 240 series ADRT series ALA1000 series ALS130, 135, 2200, 3600, 5000, 5000WB, 20000, & 25000

series ARA125 series ASR1000, 1100, & 2000 series (with HPD option) ATS1100-H series LMA & LMAC series

Motor


yy = Length in feet



Table 5-4. Individual Feedback Cables Ndrive HL Part Number (s) Description Stage/Motor

C16501-xx C16505-xx BFCMX-yy

BL FB-25DU-25DU-MAX120DM BL FB-25DU-25DU-MAX240DM Obsolete

Motor Feedback

Used On: Any brushless motor stage having a 25 pin D style connector for encoder, limits, halls and brake. BM/BMS motors (with -D25 option) ABL2000 & 8000 series ABR1000 Series ADR160 - 240 series ADRT series ALA1000 series ALS130, 135, 2200, 3600, 5000, 5000WB, 20000, & 25000

series ARA125 series ASR1000, 1100, & 2000 series (with HPD option) ATS1100-H series LMA & LMAC series

Encoder/Limits / Halls / Brake

C18391-xx C18393-xx BFCD-yy

BL FB-25DU-25DU 9DU-MAX120DM BL FB-25DU-25DU 9DU-MAX240DM Obsolete

Motor Feedback

Used On: Any Brushless motor stage having a 25 pin D style connector for encoder, halls and brake and a 9 pin D connector for limits. BM/BMS motors (with D25 option)

Encoder / Halls

/ Brake

Limits

C15291-xx C15297-xx BFC-yy

BL FB-25DU-17MS 9DU-MAX120DM BL FB-25DU-17MS 9DU-MAX240DM Obsolete

Motor Feedback

Used On: Any stage having a BM/BMS motor with a 17 pin MS style connector for encoder, halls and brake and a 9 pin D connector for limits.

Encoder / Halls

/ Brake

Limits


yy = Length in feet



5.2. Joystick Interface

The user may connect an Aerotech JI (not JBV, or JP4) joystick or their own joystick and switches to the Ndrive HL (Refer to Figure 5-1). The joystick interlock input must be set to the logic low state to indicate the joystick is connected. The zero velocity null-point for each joystick is approximately 2.5 volts. Be sure to set the JoyStickMinVoltage and JoyStickMaxVoltage task parameters. Also, the two potentiometers may be connected to analog inputs on two different Ndrive HLs since each Ndrive HL standardly has one analog input.

Subsequent drawings illustrate how to connect a single axis and a two-axis joystick to the Ndrive HL in various ways, and the cables required to so do. A two-axis joystick requires an Ndrive HL with the IOPSO option, form two analog inputs or two Ndrive HLs, each with one analog input.

When using an external potentiometer (such as a joystick) to drive the Ndrive HL analog inputs, it must be manually calibrated.

1) Set the joystick potentiometer at mid point (detent position) and record the voltage from the Nstat window.

2) Record the voltage at the minimum and maximum deflections of the potentiometer. Subtract the two voltages.

3) Set the JoyStickMaxVoltage task parameter to the mid point voltage from step 1 plus 1/2 the voltage difference from step 2.

4) Set the JoyStickMinVoltage task parameter to the mid point voltage from step 1 minus 1/2 the voltage difference from step 2.

If two different Ndrive HLs are being used to read the joystick, only one Ndrive HL should be used to provide 5 Volt power to the potentiometers. The second Ndrive HL should connect differentially to the second joystick potentiometer by connecting the Analog Input- to common and the Analog Input+ to the potentiometers wiper.

Figure 5-1. Joystick Interface



A standard Aerotech JI joystick may be connected to J205 of the Ndrive HL as a single axis joystick via the following cable, shown below (Figure 5-2 and Figure 5-3). Figure 5-2 indicates the required cable and Figure 5-3 indicates the interconnection of the joystick to the Ndrive HL.

Be sure to set only one of the JoyStickAnalogHorizInput or the JoyStickAnalogVertInput task parameters. Also, define only one axis each of the SlewPair1 through SlewPair8 task parameters.

The following drawings are shown for reference only and were complete and accurate as of this manuals release. The most recent .Dwg files and a viewer may be found on your software CD ROM.

BLU

BLKWHT

GRN

RED

+5VXT_INCOMEXT_IN2ALOG_IN+COM

NALOG_IN-AGND

EXT_IN1

8 COND. #24LENGTH A.R. SEE NOTE 2.

26 HD MALE, #K86-AA-26P, (ECK01259)BACKSHELL, #17-1725-2, (ECK01022)

ECX00570

EXT_IN3 BRN

BACKSHELL, #17-1725-2, (ECK01022)

15 LINE FEMALE "D"745493-2, ECK00783

CONNECTOR SHIELDING

PART IS OUTSIDESUCH THAT THE SILVERFOLD BACK FOIL SHIELD

IF REQUIRED.

SHIELD DRAIN WIREFOLD BACK & TWIST

& WIRE TO PIN 12 COVER

OVER GROMMET, SHIELD & DRAIN WIREWRAP 6" COPPER FOIL (EIA281)

#5 GROMMET SUPPLIEDW/BACKSHELL

INTERLOCK

S2

COM

X POT

S1

+5V

SHIELD

630B1979-2630B1979-201.DWG

Ndrive HL Joystick

(JSXT-26HD-XX)Extension Cable

C19792-XX. CONNECTOR VIEW FROM SOLDER SIDE.

JOYSTICKTO

SEE NOTE 3 FOR CONNECTOR VIEWJACKSOCKETS, #207719-3, (ECK00129)

30 = 30 DECIMETERS (3 METERS) = 10FT.CAUTION, CABLE LENGTHS (XX) ARE IN DECIMETERS

. CABLE LENGTH

EXAMPLE: C19792-30

A.R.

TONdrive HL

J205

Figure 5-2. Single Axis Joystick Interface to J205 of the Ndrive HL



620B1345-2

Ndrive HLJOYSTICK INTERCONNECT

620B1345-201.DWG

Ndrive HPJOYSTICK INTERFACE

I/OAUXJ205

FEM

ALE

CABLE

26H

D

JOYSTICK EXT.C19792-XX

JOYSTICK

JIINDUSTRIAL

NOTES:

1. USING C19792-XX CABLE WILL ONLY PROVIDE 1 AXIS OF SLEWING. REQUIRES Ndrive HP TO HAVE REV. "A" CONTROL BOARD.

2. THE JI JOYSTICK MUST BE USED WITH THE Ndrive HL. JBV OR JP4 JOYSTICK VERSIONS ARE NOT COMPATIBLE.

1

2

(C19792-XX CABLE)

Figure 5-3. Single Axis Joystick Interconnect to J205 of the Ndrive HL

A standard Aerotech JI joystick may be connected to the I/O on the IOPSO option via the following cable for a two-axis joystick. Figure 5-4 indicates the required cable and the Figure 5-5 indicates the interconnection of the joystick to the Ndrive HL.

1

23

4

7

VIO

BLUYEL

W/GRN

BLK

+5VIPIN2A1+GNDAGND

A2-A2+

16 COND. #24LENGTH A.R. SEE NOTE 2.

FERRULE, #3200014 (EIK01001) TYP. 12 PLS.ADD BRADY WIRE MARKERS SEE NOTE 3.

ECX01009

IN31213GRY

BACKSHELL, #17-1725-2, (ECK01022)

15 LINE FEMALE "D"745493-2, ECK00783

CONNECTOR SHIELDING

PART IS OUTSIDESUCH THAT THE SILVERFOLD BACK FOIL SHIELD

IF REQUIRED.

SHIELD DRAIN WIREFOLD BACK & TWIST

& WIRE TO PIN 12 COVER

OVER GROMMET, SHIELD & DRAIN WIREWRAP 6" COPPER FOIL (EIA281)

#5 GROMMET SUPPLIEDW/BACKSHELL

INTERLOCK

S2

COM

X POT

S1

+5V

SHIELD

630B1979-1630B1979-1A1.DWG

Ndrive HL Joystick

(JSXT-FLY-XX)Extension Cable

C19791-XX

TONdrive HL JOYSTICK

TO

6in.

A.R.

RED

BRN

GRN

W/BRNA1-

IN1 ORN6 Y POT

GND

JACKSOCKETS, #207719-3, (ECK00129)

CAUTION, CABLE LENGTHS (XX) ARE IN DECIMETERS30 = 30 DECIMETERS (3 METERS) = 10FT.EXAMPLE: C19791-30

2. CABLE LENGTH

FLAG WIRES WITH BRADY LABELS3. WIRE MARKERS

COMPUTER FILE NO. 630B1979-1A1.

SEE NOTE 3

TB305-1

TB303-2TB305-5

TB305-4

TB302-1

TB305-3TB302-4

TB302-3TB302-5

TB302-2TB303-1

TB303-3

-IOPSO

Figure 5-4. Two-Axis Joystick Interface to the I/O on the IOPSO Option



620B1345-1

Ndrive HLJoystick Interconnect

Joystick InterfaceNdrive HL

BLK

W/BRN

SHIELD

GRN

GRY

RED

VIO2GND

IP

+5V

IN3

1

3

A2+

A2-

GND

5

1

4

W/GRN

BRN

YELAGND

A1-

A1+ 2

3

1

ORN

BLUIN2

IN1

4

3

JI

JOYSTICKINDUSTRIAL

CABLEJOYSTICK EXT.

C19791-XX

5

TB302

TB303

TB305

IOPSO INTERFACE

NOTES:

1. USING C19791-XX CABLE WILL PROVIDE 2 AXES OF SLEWING. REQUIRES THE Ndrive HL TO HAVE THE "IOPSO" OPTION INSTALLED.

2. THE JI JOYSTICK MUST BE USED WITH THE Ndrive HL. JBV OR JP4 JOYSTICK VERSIONS ARE NOT COMPATIBLE.

2

(C19791-XX CABLE)

1

Figure 5-5. Two-Axis Joystick Connection to the I/O on the IOPSO Option



5.3. Handwheel Interface

The user may connect a handwheel or any device producing differential quadrature signals, for manual positioning of the axes. See the Nview HMI help for information on enabling the handwheel via software commands. The handwheel may be connected to J205 of the Ndrive HL as shown in Figure 5-6 below, or the I/O available on the IOPSO option, shown in subsequent Figures.

HWA32-26HD-XX

HANDWHEEL123456

5V0V

BB-N

A-NA

SUMTAKLGF-043-100

1110

212112 RED

BLKBRNBLUWHTGRN

ECX00570 CABLE8 COND. #24 SHIELDED

26 PIN HD MALE, #K86-AA-26P (ECK01259)BACKSHELL, 17-1725-2 (ECK01022)

NC

(ECZ00201)

10 FT. OR AR. LENGTH

100 LINES/REV

HANDWHEEL(HWA32-26HD-XX)

Ndrive HL

HWA32-26HD-XX

630B1983-201.DWG

630B1983-2

TYPE 4 - MIA424

S/N: XXXXXX

MODEL:HWA32-26HD-XX

XXXXXX = WORK ORDER NUMBER

XX = CABLE LENGTH IN DECIMETERS

1. INSTALL LABEL TO BACK OF HANDWHEEL

2. CABLE LENGTHCAUTION, CABLE LENGTHS (XX) ARE IN DECIMETERSEXAMPLE: HWA32-26HD-30

30 = 30 DECIMETERS (3 METERS) = 10FT.

2

630B1983-2 REV. -

TERMINAL, #52949, AMP (EIK00234) TYP. 6 PLS.ADD BRADY WIRE MARKERS TO TERMINALS.

SEE NOTE 3 FOR CONNECTOR VIEW

3. CONNECTOR VIEW FROM SOLDER SIDE.

A.R.

SIN

COS-NCOS

SIN-N

COM5V

TONdrive HL

J205

Figure 5-6. Handwheel Interconnection to J205 of the Ndrive HL

A handwheel with flying leads (no connector) may also be connected to the Ndrive HL via the Aerotech BBA32 to J205, per the next two drawings.



HWA32-FLY-XX

HANDWHEEL123456

5V0V

BB-N

A-NA

SUMTAKLGF-043-100

1110

212112 RED

BLKBRNBLUWHTGRN

ECX00570 CABLE8 COND. #24 SHIELDED

FERRULE, #3200014 (EIK01001) TYP. 7 PLS.ADD BRADY WIRE MARKERS TO WIRES.

NC

(ECZ00201)

10 FT. OR AR. LENGTH

100 LINES/REV

SIN

COS-NCOS

SIN-N

COM5V

HANDWHEEL(HWA32-FLY-XX)

Ndrive HL

HWA32-FLY-XX630B1983-101.DWG

630B1983-1

TYPE 4 - MIA00424

S/N: XXXXXX

MODEL:HWA32-FLY-XX

XXXXXX = WORK ORDER NUMBER

XX = CABLE LENGTH IN DECIMETERS

1. INSTALL LABEL TO BACK OF HANDWHEEL

2. CABLE LENGTHCAUTION, CABLE LENGTHS (XX) ARE IN DECIMETERSEXAMPLE: HWA32-FLY-30

30 = 30 DECIMETERS (3 METERS) = 10FT.

2

630B1983-1 REV. -

TERMINAL, #52949, AMP (EIK00234) TYP. 6 PLS.ADD BRADY WIRE MARKERS TO TERMINALS.

GND G

A.R.

6in.

BBA32 BREAK-OUT BLOCK. REFERENCE 620B1344-1.3. THIS HANDWHEEL IS INTENDED TO BE USED WITH THE

TONdrive HL

J205VIA

BBA32

Figure 5-7. Handwheel with Flying Leads (no connector)

620B1343-1

Ndrive HL BBA32AUX I/O INTERCONNECT

620B1343-101.DWG

Ndrive HLBBA32 AUX I/O INTERFACE

I/OAUXJ205

FEM

ALE ECZ01231

10. AUX_COS+

12. +5V11. AUX_COS-

14. ANALOG_IN-5. OPTO2+

7. EXT_OUT16. OPTO2-

8. EXT_OUT29. EXT_OUT3

17. EXT_IN118. EXT_IN2

15. EXT_OUTCOM16. EXT_OUT4

1. AUX_SIN+

4. OPTO1-3. OPTO1+2. AUX_SIN-

13. ANALOG_IN+23. AGND24. EXT_INCOM25. EXT_IN3

22. ANALOG1_OUT

20. AUX_MRK+19. AUX_MRK-

21. COM

PHOENIX 26-PIN HDBREAKOUT MODULEECZ01230SHOWN FOR REFERENCE

BBA32AUX I/O

INTERFACE 26. EXT_IN4

26H

D

M/F CABLE26 PIN HD

2.5FT.

NOTES:

THE BBA32 CONSISTS OF THE FOLLOWING PARTS: 1 - ECZ01230 (PHOENIX BREAK-OUT MODULE) 1 - ECZ01231 (26 PIN HD M/F CABLE 2.5FT.)

Figure 5-8. BBA32 Interface used to connect a Handwheel with flying leads (no connector)

∇ ∇ ∇

Ndrive HL Users Manual Troubleshooting


CHAPTER 6: TROUBLESHOOTING

6.1. Problems, Causes, and Solutions

This section covers symptoms, probable causes, and solutions related to Ndrive HL operation. Table 6-1 lists the most common symptoms of irregular operation and the possible causes and solutions for these faults. More information can be found in the Nview HMI help.

Before performing the tests described in Table 6-1, be aware of lethal voltages inside the controller and at the input and output power connections. A qualified service technician or electrician should perform these tests.

Table 6-1. Amplifier Faults, Causes, and Solutions Symptom Possible Cause and Solution

Motor spins uncontrollably. Encoder (sine and cosine) signals are improperly connected. See Section 2.5. for motor phasing information.

Brushless motor will not spin.

Motor phases A, B, and C connected incorrectly relative to Hall A, Hall B, and Hall C inputs. See Section 2.5. for motor phasing information.

Amplifier faults (ENABLE LED de-energizes) when the motor decelerates.

Bus over voltage detected (Ndrive HL). This condition indicates an excessive regeneration condition.

Amplifier Faults ("ENABLE" LED de-energizes).

1. RMS current exceeded - run at a lower current. 2. Over temperature condition - Turn off and let amplifier

cool down. Provide better ventilation. 3. Defective on board power supply - Return for repair.

Troubleshooting Ndrive HL Users Manual


6.2. Ndrive HL Control Board Test Points

The following test point is available internal to the Ndrive HL.

Table 6-2. Ndrive HL Control Board Test Point Test Point Function TP4 Signal Common (Analog and Digital)



6.3. Ndrive HL Control Board Assembly

Figure 6-1 highlights the important components located on the control board assembly. The Ndrive HL is jumper selectable, providing the user with quick reconfiguration capability of the few operating modes not configurable by software. Table 6-3 list the jumpers and the default configurations for the Ndrive HL Control board (the -IOPSO option board and jumper configurations are listed in Chapter 4).

S2 defines the Ndrive HL device number and is the only user configured switch/jumper on the control board (see Table 2-5).

B1

J10 J9

J11

JP5

F4

J204

JP7

S2

J205TB201J206

J207

S1

JP4

JP3

JP2

P10J12

J201J202J203

F1

F3F2

JP6TP4

P9JP1

P8

Figure 6-1. Ndrive HL Control Board Assembly (690D1577 Rev. A)



Table 6-3. Ndrive HL Control Board Jumper Selections Jumpers Position Function

1-2 Signal Common isolated from Frame Ground (Chassis) JP1

2-3 * Signal Common connected to Frame Ground (Chassis) All in * Auxiliary Encoder Channel 2 is an input JP2

JP3 JP4 All out Auxiliary Encoder Channel 2 is an output

In * 100 Ohm Terminator present for RS-485 port on J301 JP5

Out 100 Ohm Terminator not present for RS-485 port on J301 JP6A 1-2 * In for 100 Terminator on RS-422 Port 2 (J301, J302, J303) JP6B 3-4 * In for 100 Terminator on RS-422 Port 1 (J301, J302, J303) JP6C 5-6 * In for 100 Terminator on RS-422 Port 3 (J302, J303) JP6D 7-8 * In for 100 Terminator on RS-422 Port 4 (J302, J303)

1-2 Watch Dog Timer Enabled JP7

2-3 * Watch Dog Timer Disabled

* indicates factory default setting

Switch S1 is for factory use only and should not be changed by the user.

The Ndrive HL control board has no user-replaceable fuses.



6.4. Ndrive HL Motor Power Board Assembly

Figure 6-2 highlights the important jumpers and components located on the Ndrive HL power board.

J8

J9

J10

DS1

F3 J11

F1 F2

JP14

TB101

Figure 6-2. Ndrive HL Motor Power Board, (690D1589 Rev 0)

Remove AC power from unit before removing the cover.



Table 6-4. Ndrive HL Motor Power Board Jumper Selections Jumper Selection Description

1-2 IN, 2-3 OUT Signal common connected to chassis (Default) JP14

1-2 OUT, 2-3 IN Signal common not connected to chassis

Table 6-5. Ndrive HL Motor Power Board Fuse Information Fuse Description Size

Ndrive HL10-40: 5 A S.B., 3AG Ndrive HL20-40: 10 A S.B., 3AG F1, F2 Bus Supply Fuses (Motor Power) Ndrive HL10-80: 5 A S.B., 3AG

F3 +5 Volt Fusing for Power Board 2 A S.B.

Table 6-6. Ndrive HL Motor Power Board Test Point Information Test Point Description TP1 +12V TP2 -12V TP3 +5V TP4 Common TP10 Phase A Common TP11 Phase B Common TP12 Phase C Common



6.5. Ndrive HL Power Supply Board Assembly

Figure 6-3 highlights the important components located on the Ndrive HL Power supply Board. Table 6-4 lists the jumpers and the default configurations for the amplifier.

Figure 6-3. Ndrive HL Power Supply Board, (690D1588 Rev -)

Table 6-7. Jumper Selections (Line Voltage) on Power Supply Board Input Power JP7 JP8 JP9 JP10 F2 (Fuse)

A (115 V) 1-2 1-2 2-3 2-3 10 ASB B (230 V) 1-2 1-2 1-2 1-2 5 ASB C (100 V) 2-3 2-3 2-3 2-3 10 ASB D (200 V) 2-3 2-3 1-2 1-2 5 ASB

Table 6-8. Jumper Selections (Bus Voltage) on Power Supply Board Standard Voltage JP1 JP2 JP3 JP4 JP5 JP6

40 VDC IN IN IN IN 80 VDC IN IN

Remove AC power from the unit before removing the cover.

JP12 must always be set 1-2.

Ndrive HL

JP12 1-2



Table 6-9. Ndrive HL Power Supply Board Jumper Selections Jumpers Positions Function

1-2* Bus under-voltage detection enabled JP5

2-3 Bus under-voltage detection disabled 1-2* FireWire Bus power source

JP6 2-3 Disable Fire Wire Bus power source

* Factory Default

All jumpers are factory-configured and should not be changed by the user.

Table 6-10. Ndrive HL Power Supply Board Fuse Information Fuse Description Size F1 AC Control Power Fuse 3A S.B. F2 See Table Table 6-7. See Table Table 6-7. F3 DC Control Power Fuse .5 A S.B. R6 AC Inrush Limiter Circuit Fusing 3A S.B.

F2 is a standard socketed fuse. F1, F3 and R6 (Fuse) are soldered to the circuit board. See Section 6.8. for fuse replacement information.



6.6. LED Indicators

The following LEDs are available on each Ndrive HL. Full Ndrive HL status is available via the Nmotion SMC and its utilities.

Table 6-11. LED Indicator Description Label Description LIMIT+ Positive end of travel limit input active FAULT An axis fault has occurred, see the Fault axis parameter POS ERR Position Error has exceeded the ThresholdPosError axis parameter ENABLE Axis is enabled KERNEL Nmotion SMC controller is running LMT- Negative end of travel limit input active RMS RMS motor current has exceeded the ThresholdAvgIAmp axis parameter

CLMT Current is clamped at the value determined by the ThresholdClampIAmp axis parameter

INPOS Axis is in position ACTV Reset indicator Active Axis is enabled Power Ndrive HL has control power



6.7. JTAG Programming Connector

This connector is for Aerotech internal use only.

Table 6-12. JTAG Programming Connector Internal (P10) Pin # Label Description In/Out/Bi. 1 TDI JTAG Data Input Input 2 Common Signal Common N.A. 3 TDO JTAG Data Output Output 4 Common Signal Common N.A. 5 TCK JTAG Programming Clock Input 6 Common Signal Common N.A. 7 JTAG-TDI Test Data Input Input 8 - Key Position (No Connection) N.A 9 Reset Reset Input 10 TMS Test Mode Select Input 11 Power 3.3 Volt Standard (5 Volt Optional) Output 12 JTAG-TDO Test Data Output Output 13 DE-N Data Enable Input 14 TRST-N Test Reset Input



6.8. Fuse / Battery Replacement

Table 6-14 lists the manufacturer and Aerotechs part number for typical replacement fuses. Additional fuse information can be found on the system drawing supplied with the unit.

Always disconnect the mains power connection before opening the Ndrive HL chassis.

Table 6-13. Ndrive HL Power Supply Board Fuse Information, (690D1588) Fuse Description Third Party P/N Aerotech P/N Size F1 AC Control Power Fuse Littlefuse 230003S EIF01013 3A S.B.

-A (115 VAC) Littlefuse 326010 EIF00117 10 A S.B. -B (230 VAC) Littlefuse 313005 EIF00105 5 A S.B. -C (100 VAC) Littlefuse 326010 EIF00117 10 A S.B.

F2

-D (200 VAC) Littlefuse 313005 EIF00105 5 A S.B. F3 DC Control Power Fuse Littlefuse 230.500 EIF01010 .5 A S.B. R6 AC Inrush Limiter Fuse Littlefuse 230003S EIF01013 3A S.B.

F2 is a standard socketed fuse. F1, F3 and R6 (Fuse) are soldered to the circuit board.

Table 6-14. Ndrive HL Motor Power Board Fuse Information, (690D1589) Fuse Description Third Party P/N Aerotech P/N Size

NL10-40 Littlefuse 313005 EIF00105 5 A S.B. NL20-40 Littlefuse 326010 EIF00117 10 A S.B. F1, F2

Supply main fusing for AC1 VAC bus input NL10-80 Littlefuse 326010 EIF00105 5 A S.B.

F3 +5 Volt Fuse Littlefuse 0430002 EIF00003 2A S.B.

F1, F2 are normal, socketed fuses. F3 is soldered to the circuit board.

Table 6-15. Battery Replacement Part Number (Ndrive HL Control Board) Battery Description Third Party P/N Aerotech P/N B1 3 V Coin Cell RAY-O-VAC BR1225 ECZ01079



6.9. Preventative Maintenance

The Ndrive HL and external wiring should be inspected monthly. Inspections may be required at more frequent intervals, depending on the environment and use of the system. Table 6-16 lists the recommended checks that should be made during these inspections.

The Ndrive HL (all Aerotech equipment) is not to be used in a manner not specified by Aerotech, Inc.

Table 6-16. Preventative Maintenance Check Action to be Taken Visually Check chassis for loose or damaged parts / hardware. Note: Internal inspection is not required.

Parts should be repaired as required. If internal damage is suspected, these parts should be checked and repairs made if necessary.

Inspect cooling vents. Remove any accumulated material from vents.

Check for fluids or electrically conductive material exposure.

Any fluids or electrically conductive material must not be permitted to enter the Ndrive HL. Note: Disconnect power to avoid shock hazard.

Visually inspect all cables and connections.

Tighten or re-secure any loose connections. Replace worn or frayed cables. Replace broken connectors.

6.9.1. Cleaning The Ndrive HL should be wiped with a clean, dry (or slightly damp with water), soft cloth. Fluids and sprays are not recommended because of the chance for internal contamination, which may result in electrical shorts and/or corrosion. The electrical power must be disconnected from the Ndrive HL while cleaning. Do not allow cleaning substances to enter the Ndrive HL or on to any of the connectors. Cleaning labels should be avoided to prevent removal of labels.

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Ndrive HL Users Manual Glossary of Terms

www.aerotech.com A-1

APPENDIX A: GLOSSARY of TERMS Abbe Error The positioning error resulting from angular motion and an offset

between the measuring device and the point of interest.

Abbe Offset The value of the offset between the measuring device and the point of interest.

Absolute Move A move referenced to a known point or datum.

Absolute Programming A positioning coordinate reference where all positions are specified relative to a reference or home position.

AC Brushless Servo A servomotor with stationary windings in the stator assembly and permanent magnet rotor. AC brushless generally refers to a sinusoidally wound motor (such as BM series) to be commutated via sinusoidal current waveform. (see DC brushless servo)

Acceleration The change in velocity as a function of time.

Accuracy An absolute measurement defining the difference between actual and commanded position.

Accuracy Grade In reference to an encoder grating, accuracy grade is the tolerance of the placement of the graduations on the encoder scale.

ASCII American Standard Code for Information Interchange. This code assigns a number to each numeral and letter of the alphabet. Information can then be transmitted between machines as a series of binary numbers.

Axial Run-Out Positioning error of the rotary stage in the vertical direction when the tabletop is oriented in the horizontal plane. Axial run-out is defined as the total indicator reading on a spherical ball positioned 50 mm above the tabletop and centered on the axis of rotation.

Axis of Rotation A centerline about which rotation occurs.

Back EMF, Kemf The voltage generated when a permanent magnet motor is rotated. This voltage is proportional to motor speed and is present whether or not the motor windings are energized.

Backlash A component of bidirectional repeatability, it is the non-responsiveness of the system load to reversal of input command.

Ball Screw A precision device for translating rotary motion into linear motion. A lead screw is a low-cost lower performance device performing the same function. Unit consists of an externally threaded screw and an internally threaded ball nut.

Ball Screw Lead The linear distance a carriage will travel for one revolution of the ball screw (lead screw).

Bandwidth A measurement, expressed in frequency (hertz), of the range which an amplifier or motor can respond to an input command from DC to -3dB on a frequency sweep.

Baud Rate The number of bits transmitted per second on a serial communication channel such as RS-232 or modem.

Glossary of Terms Ndrive HL Users Manual

A-2 www.aerotech.com

BCD Binary Coded Decimal - A number system using four bits to represent 0-F (15).

Bearing A support mechanism allowing relative motion between two surfaces loaded against each other. This can be a rotary ball bearing, linear slide bearing, or air bearing (zero friction).

Bidirectional Repeatability See Repeatability.

CAM Profile A technique used to perform nonlinear motion that is electronically similar to the motion achieved with mechanical cams.

Cantilevered Load A load not symmetrically mounted on a stage.

Closed Loop A broad term relating to any system where the output is measured and compared to the input. Output is adjusted to reach the desired condition.

CNC Computer Numerical Control. A computer-based motion control device programmable in numerical word address format.

Coefficient of Friction Defined as the ratio of the force required to move a given load to the magnitude of that load.

Cogging Non-uniform angular/linear velocity. Cogging appears as a jerkiness, especially at low speeds, and is due to magnetic poles attracting to steel laminations.

Commutation The action of steering currents to the proper motor phases to produce optimum motor torque/force. In brush-type motors, commutation is done electromechanically via the brushes and commutator. A brushless motor is electronically commutated using a position feedback device such as an encoder or Hall effect devices. Stepping motors are electronically commutated without feedback in an open-loop fashion.

Commutation, 6-Step Also referred to as trapezoidal commutation. The process of switching motor phase current based on three Hall effect signals spaced 120 electrical degrees beginning 30 degrees into the electrical cycle. This method is the easiest for commutation of brushless motors.

Commutation,

Modified 6-Step

Also referred to as modified sine commutation. The process of switching motor phase current based on three Hall effect signals spaced 120 electrical degrees beginning at 0 electrical degrees. This method is slightly more difficult to implement than standard 6-step, but more closely approximates the motors back EMF. The result is smoother control and less ripple. Aerotechs BA series self-commutate using this method.

Commutation, Sinusoidal The process of switching motor phase current based on motor position information, usually from an encoder. In this method, the three phase currents are switched in very small increments that closely resemble the motors back emf. Sinusoidal commutation requires digital signal processing to convert position information into three-phase current values and, consequently, is most expensive to implement. The result, however, is the best possible control. All Aerotech controllers, as well as the BAS series amplifiers, commutate using this method.



Coordinated Motion Multi-axis motion where the position of each axis is dependent on the other axis, such that the path and velocity of a move can be accurately controlled. Drawing a circle requires coordinated motion.

Critical Speed A term used in the specification of a lead screw or ball screw indicating the maximum rotation speed before resonance occurs. This speed limit is a function of the screw diameter, distance between support bearings, and bearing rigidity.

Current Command Motor driver or amplifier configuration where the input signal is commanding motor current directly, which translates to motor torque/force at the motor output. Brushless motors can be commutated directly from a controller that can output current phase A and B commands.

Current, Peak An allowable current to run a motor above its rated load, usually during starting conditions. Peak current listed on a data sheet is usually the highest current safely allowed to the motor.

Current, RMS Root Mean Square. Average of effective currents over an amount of time. This current is calculated based on the load and duty cycle of the application.

Cycle When motion is repeated (move and dwell) such as repetitive back-and-forth motion.

DC Brushless Servo A servomotor with stationary windings in the stator assembly and permanent magnet rotor. (See AC Brushless Servo)

Deceleration The change in velocity as a function of time.

Duty Cycle For a repetitive cycle, the ratio of on-time to total cycle time used to determine a motors RMS current and torque/force.

Dwell Time Time in a cycle at which no motion occurs. Used in the calculation of RMS power.

Efficiency Ratio of input power vs. output power.

Electronic Gearing Technique used to electrically simulate mechanical gearing. Causes one closed loop axis to be slaved to another open or closed loop axis with a variable ratio.

Encoder Marker Once-per-revolution signal provided by some incremental encoders to accurately specify a reference point within that revolution. Also known as Zero Reference Signal or Index Pulse.

Encoder Resolution Measure of the smallest positional change, which can be detected by the encoder. A 1000-line encoder with a quadrature output will produce 4000 counts per revolution.

Encoder, Incremental Position encoding device in which the output is a series of pulses relative to the amount of movement.

Feedback Signal that provides process or loop information such as speed, torque, and position back to the controller to produce a closed-loop system.

Flatness (of travel) Measure of the vertical deviation of a stage as it travels in a horizontal plane.

Force, Continuous The value of force that a particular motor can produce in a continuous stall or running (as calculated by the RMS values) condition.



Force, Peak The maximum value of force that a particular motor can produce. When sizing for a specific application, the peak force is usually that required during acceleration and deceleration of the move profile. The peak force is used in conjunction with the continuous force and duty cycle to calculate the RMS force required by the application.

Friction The resistance to motion between two surfaces in contact with each other.

G.P.I.B. A standard protocol, analogous to RS-232, for transmitting digital information. The G.P.I.B. interface (IEEE-488) transmits data in parallel instead of serial format. (See IEEE-488)

Gain Comparison or ratio of the output signal and the input signal. In general, the higher the system gain, the higher the response.

Grating Period Actual distance between graduations on an encoder.

Hall Effect Sensors Feedback device (HED) used in a brushless servo system to provide information for the amplifier to electronically commutate the motor.

HED Hall Effect Device. (See Hall Effect Sensors)

HMI Human Machine Interface. Used as a means of getting operator data into the system. (See MMI)

Home Reference position for all absolute positioning movements. Usually defined by a home limit switch and/or encoder marker.

Home Switch A sensor used to determine an accurate starting position for the home cycle.

Hysteresis A component of bidirectional repeatability. Hysteresis is the deviation between actual and commanded position and is created by the elastic forces in the drive systems.

I/O Input / Output. The reception and transmission of information between control devices using discrete connection points.

IEEE-488 A set of codes and formats to be used by devices connected via a parallel bus system. This standard also defines communication protocols that are necessary for message exchanges, and further defines common commands and characteristics. (See G.P.I.B.)

Incremental Move A move referenced from its starting point (relative move).

Inertia The physical property of an object to resist changes in velocity when acted upon by an outside force. Inertia is dependent upon the mass and shape of an object.

Lead Error The deviation of a lead screw or ball screw from its nominal pitch.

Lead Screw A device for translating rotary motion into linear motion. Unit consists of an externally threaded screw and an internally threaded carriage (nut). (See Ball Screw)

Life The minimum rated lifetime of a stage at maximum payload while maintaining positioning specifications.

Limit Switch A sensor used to determine the end of travel on a linear motion assembly.



Limits Sensors called limits that alert the control electronics that the physical end of travel is being approached and motion should stop.

Linear Motor A motor consisting of 2 parts, typically a moving coil and stationary magnet track. When driven with a standard servo amplifier, it creates a thrust force along the longitudinal axis of the magnet track.

Load Carrying Capability The maximum recommended payload that does not degrade the listed specifications for a mechanical stage.

Master-Slave Type of coordinated motion control where the master axis position is used to generate one or more slave axis position commands.

MMI Man Machine Interface used as a means of getting operator data into the system. (See HMI)

Motion Profile A method of describing a process in terms of velocity, time, and position.

Motor Brush The conductive element in a DC brush-type motor used to transfer current to the internal windings.

Motor, Brushless Type of direct current motor that utilizes electronic commutation rather than brushes to transfer current.

Motor, Stepping Specialized motor that allows discrete positioning without feedback. Used for non-critical, low power applications, since positional information is easily lost if acceleration or velocity limits are exceeded.

NC Numerical Control. Automated equipment or process used for contouring or positioning. (See CNC). Also, a Normally-Closed switch.

NO A Normally-Open switch.

NEMA National Electrical Manufacturers Association. Sets standards for motors and other industrial electrical equipment.

Non-Volatile Memory Memory in a system that maintains information when power is removed.

Open Collector A signal output that is performed with a transistor. Open collector output acts like a switch closure with one end of the switch at circuit common potential and the other end of the switch accessible.

Open Loop Control circuit that has an input signal only, and thus cannot make any corrections based on external influences.

Operator Interface Device that allows the operator to communicate with a machine. A keyboard or thumbwheel is used to enter instructions into a machine. (See HMI or MMI)

Optical Encoder A linear or angular position feedback device using light fringes to develop position information.

Opto-Isolated System or circuit that transmits signal with no direct electrical connections, using photoelectric coupling between elements.

Orthogonality The condition of a surface or axis perpendicular (offset 90°) to a second surface or axis. Orthogonality specification refers to the



error from 90° from which two surfaces of axes are aligned.

Overshoot In a servo system, referred to the amount of velocity and/or position overrun from the input command. Overshoot is a result of many factors including mechanical structure, tuning gains, servo controller capability, and inertial mismatch.

PID A group of gain terms in classical control theory (Proportional Integral Derivative) used in compensation of a closed-loop system. The terms are optimally adjusted to have the output response equal the input command. Aerotech controllers utilize the more sophisticated PID FVFA loop which incorporates additional terms for greater system performance.

Pitch (of travel) Angular motion of a carriage around an axis perpendicular to the motion direction and perpendicular to the yaw axis.

Pitch Error Positioning error resulting from a pitching motion.

PLC Programmable Logic Controller. A programmable device that utilizes ladder logic to control a number of input and output discrete devices.

PWM Pulse Width Modulation. Switch-mode technique used in amplifiers and drivers to control motor current. The output voltage is constant and switched at the bus value (160 VDC with a 115 VAC input line).

Quadrature Refers to the property of position transducers that allows them to detect direction of motion using the phase relationship of two signal channels. A 1000-line encoder will yield 4000 counts via quadrature.

Radial Run-Out Positioning error of the rotary stage in the horizontal direction when the tabletop is oriented in the horizontal plane. Radial run-out is defined as the total indicator reading on a spherical ball positioned 50 mm above the tabletop and centered on the axis of rotation.

Ramp Time Time it takes to accelerate from one velocity to another.

Range The maximum allowable travel of a positioning stage.

RDC Resolver to Digital Converter. Electronic component that converts the analog signals from a resolver (transmitter type) into a digital word representing angular position.

Repeatability The maximum deviation from the mean (each side) when repeatedly approaching a position. Unidirectional repeatability refers to the value established by moving toward a position in the same direction. Bidirectional repeatability refers to the value established by moving toward a position in the same or opposite direction.

Resolution The smallest change in distance that a device can measure.

Retro-reflector An optical element with the property that an input light beam is reflected and returns along the same angle as the input beam. Used with laser interferometers.

Roll (of travel) Angular motion of a carriage around an axis parallel to the motion direction and perpendicular to the yaw axis.

Roll Error Positioning error resulting from a roll motion.



Rotor The rotating part of a magnetic structure. In a motor, the rotor is connected to the motor shaft.

RS-232C Industry standard for sending signals utilizing a single-ended driver/receiver circuit. As such, the maximum distance is limited based on the baud rate setting but is typically 50-100 feet. This standard defines pin assignments, handshaking, and signal levels for receiving and sending devices.

RS-274 Industry standard programming language. Also referred to as G-code machine programming. A command set specific for the machine tool industry that defines geometric moves.

RS-422 Industry communication standard for sending signals over distances up to 4000 feet. Standard line driver encoder interfaces utilize RS-422 because of the noise immunity.

Run-Out The deviation from the desired form of a surface during full rotation (360 degrees) about an axis. Run-out is measured as total indicated reading (TIR). For a rotary stage, axis run-out refers to the deviation of the axis of rotation from the theoretical axis of rotation.

Servo System Refers to a closed loop control system where a command is issued for a change in position and the change is then verified via a feedback system.

Settling Time Time required for a motion system to cease motion once the command for motion has ended.

Shaft Radial Load Maximum radial load that can be applied to the end of the motor shaft at maximum motor speed.

Shaft Run-Out Deviation from straight-line travel.

Slot-less Describes the type of laminations used in a motor that eliminates cogging torque due to magnetic attraction of the rotor to the stator slots.

Stator Non-rotating part of a magnetic structure. In a motor, the stator usually contains the mounting surface, bearings, and non-rotating windings.

Stiction Friction encountered when accelerating an object from a stationary position. Static friction is always greater than moving friction, and limits the smallest possible increment of movement.

Straightness of Travel Measure of the side-to-side deviation of a stage as it travels in a horizontal plane.

Torque Rotary equivalent to force. Equal to the product of the force perpendicular to the radius of motion and distance from the center of rotation to the point where the force is applied.

Torque, Continuous Torque needed to drive a load over a continuous time.

Torque, Peak Maximum amount of torque a motor can deliver when the highest allowable peak currents are applied.

Torque, RMS Root Mean Square is a mathematical method to determine a steadfast or average torque for a motor.

Torque, Stall The maximum torque without burning out the motor.

Total Indicated Reading The full indicator reading observed when a dial indicator is in



(TIR) contact with the part surface during one full revolution of the part about its axis of rotation.

Tuning In a servo system, the process of optimizing loop gains (usually PID terms) to achieve the desired response from a stage or mechanism from an input command.

Unidirectional Repeatability See Repeatability

Velocity Command Motor driver or amplifier configuration where the input signal is commanding motor velocity. Motors with analog tachometers are normally driven by this driver configuration.

Wobble An irregular, non-repeatable rocking or staggering motion of the table top of a rotary stage. Wobble is defined as an angular error between the actual axis of rotation and the theoretical axis of rotation.

Yaw (of travel) Rotation about the vertical axis, perpendicular to the axis of travel. Angular movement (error) that affects straightness and positioning accuracy.

Yaw Error Positioning error resulting from a yaw motion.

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Ndrive HL Users Manual Warranty and Field Service

www.aerotech.com B-1

APPENDIX B: WARRANTY and FIELD SERVICE Aerotech, Inc. warrants its products to be free from defects caused by faulty materials or poor workmanship for a minimum period of one year from date of shipment from Aerotech. Aerotech's liability is limited to replacing, repairing or issuing credit, at its option, for any products that are returned by the original purchaser during the warranty period. Aerotech makes no warranty that its products are fit for the use or purpose to which they may be put by the buyer, where or not such use or purpose has been disclosed to Aerotech in specifications or drawings previously or subsequently provided, or whether or not Aerotech's products are specifically designed and/or manufactured for buyer's use or purpose. Aerotech's liability or any claim for loss or damage arising out of the sale, resale or use of any of its products shall in no event exceed the selling price of the unit.

Aerotech, Inc. warrants its laser products to the original purchaser for a minimum period of one year from date of shipment. This warranty covers defects in workmanship and material and is voided for all laser power supplies, plasma tubes and laser systems subject to electrical or physical abuse, tampering (such as opening the housing or removal of the serial tag) or improper operation as determined by Aerotech. This warranty is also voided for failure to comply with Aerotech's return procedures.

Laser Products

Claims for shipment damage (evident or concealed) must be filed with the carrier by the buyer. Aerotech must be notified within (30) days of shipment of incorrect materials. No product may be returned, whether in warranty or out of warranty, without first obtaining approval from Aerotech. No credit will be given nor repairs made for products returned without such approval. Any returned product(s) must be accompanied by a return authorization number. The return authorization number may be obtained by calling an Aerotech service center. Products must be returned, prepaid, to an Aerotech service center (no C.O.D. or Collect Freight accepted). The status of any product returned later than (30) days after the issuance of a return authorization number will be subject to review.

Return Procedure

After Aerotech's examination, warranty or out-of-warranty status will be determined. If upon Aerotech's examination a warranted defect exists, then the product(s) will be repaired at no charge and shipped, prepaid, back to the buyer. If the buyer desires an airfreight return, the product(s) will be shipped collect. Warranty repairs do not extend the original warranty period.

Returned Product Warranty Determination

After Aerotech's examination, the buyer shall be notified of the repair cost. At such time, the buyer must issue a valid purchase order to cover the cost of the repair and freight, or authorize the product(s) to be shipped back as is, at the buyer's expense. Failure to obtain a purchase order number or approval within (30) days of notification will result in the product(s) being returned as is, at the buyer's expense. Repair work is warranted for (90) days from date of shipment. Replacement components are warranted for one year from date of shipment.

Returned Product Non-warranty Determination

At times, the buyer may desire to expedite a repair. Regardless of warranty or out-of-warranty status, the buyer must issue a valid purchase order to cover the added rush service cost. Rush service is subject to Aerotech's approval.

Rush Service

Warranty and Field Service Ndrive HL Users Manual

B-2 www.aerotech.com

On-site Warranty Repair

If an Aerotech product cannot be made functional by telephone assistance or by sending and having the customer install replacement parts, and cannot be returned to the Aerotech service center for repair, and if Aerotech determines the problem could be warranty-related, then the following policy applies:

Aerotech will provide an on-site field service representative in a reasonable amount of time, provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs. For warranty field repairs, the customer will not be charged for the cost of labor and material. If service is rendered at times other than normal work periods, then special service rates apply.

If during the on-site repair it is determined the problem is not warranty related, then the terms and conditions stated in the following "On-Site Non-Warranty Repair" section apply.

On-site Non-warranty Repair

If any Aerotech product cannot be made functional by telephone assistance or purchased replacement parts, and cannot be returned to the Aerotech service center for repair, then the following field service policy applies:

Aerotech will provide an on-site field service representative in a reasonable amount of time, provided that the customer issues a valid purchase order to Aerotech covering all transportation and subsistence costs and the prevailing labor cost, including travel time, necessary to complete the repair.

Company Address Aerotech, Inc.

101 Zeta Drive

Pittsburgh, PA

15238-2897

Phone: (412) 963-7470

Fax: (412) 963-7459

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Ndrive HL Users Manual Manual Updates

www.aerotech.com C-1

APPENDIX C: MANUAL UPDATES

C.1. Current Changes

Version Change Sections Updated/Affected Removed MXU option For Aerotech Use: Issue Tracker ID 538

All

Updated motor wiring color codes For Aerotech Use: Issue Tracker ID 730

Section 2.4

Added IOPSOH option Section 4.1 Updated PSO schematic Figure 4-15

1.08

Updated Interconnection Cable Part Numbers Table 5-1

Updated Analog Input schematic and Text Figure 4-9 and Page 4-9 1.08b

Manual Updates Ndrive HL Users Manual

C-2 www.aerotech.com

C.2. Archive of Changes

Version Reason Sections Updated/Affected Corrected typo. in Brake circuit. Fig. 4-4

1.07 Added notes to Brake section. Section 4.1.3. 1.06 Updated product name and pictures to new product color. 1.05 All changes made for Version 1.5 were typographic only.

Line Voltage Jumpers Table 6-5 1.04

Fuse Information Tables 6-6, 6-7, 6-9, 6-12 & 6-13 Ndrive HL 10-40: 5A S.B. Ndrive HL 20-40: 10A S.B.

1.03

Power board Fuse Value (F1 and F2) Ndrive HL 10-80: 5A S.B.

Ndrive HL Users Manual Index

www.aerotech.com Index-1

INDEX

< < 70 VAC AC Bus Input Power, 2-2

1 10/100BASE-T Ethernet, 1-5, 4-22

4 4N33, 4-15

6 6N136, 4-15

A AC Power Connections, 2-2 AL1, 2-2 AL2, 2-2 Amplifier Current Limitations, 1-8 Amplifier Faults, 6-1 Amplifier Related Problems, 6-1 Analog Inputs (TB302), 4-9 Analog Output Connector Pinouts, 4-3 Auxiliary I/O

Connector Pinouts, 3-1, 3-3, 3-5, 3-6 -AUXPWR, 1-5 -AUXPWR Option, 2-2

B Battery, 6-9 Battery Replacement, 6-9 Brake / Relay (TB301) Current

Specifications, 4-4 Brake / Relay (TB301) Voltage

Specifications, 4-4 Brake / Relay Connector Pinouts, 4-5 Brake Configuration Jumpers, 4-3 Brushless Motor Configuration, 2-7, 2-9, 2-

10 Bus Power Supply, 1-4

C Cleaning, 6-10 Connector, 1-3 Connector Pinouts

Auxiliary I/O, 3-1, 3-3, 3-5, 3-6 FireWire, 3-23

J205, 3-1, 3-3, 3-5, 3-6 J206, 3-21 J207, 3-12, 3-14, 3-15 Motor Feedback, 3-12, 3-14, 3-15 RS-232/RS-422, 3-21

Continuous Output Current, 1-5 Control Board, 6-2

Assembly, 6-2 Jumpers, 6-2, 6-3 Test Points, 6-2

Control Board Options, 1-5 -DUALPSO, 1-5 ENET, 1-5 MXH, 1-5 MXU4096, 1-5 MXU65536, 1-5 PSOOPTO1, 1-5 PSOOPTO2, 1-5 PSOOPTO3, 1-5 -TRIPLEPSO, 1-5

D DC Brush Motor Configuration, 2-7 Determining Proper Connections to the

NDrive Equipment, 2-12 Test, 2-12

Device Settings, 2-19 Drive Package, 1-4 -DUALPSO, 1-5

E Electrical Specifications, 1-6 Encoder Phasing, 2-16 -ENET, 1-5, 4-22 Environmental Specifications

Humidity, 1-10 Temperature, 1-10

Operating, 1-10 Storage, 1-10

Ethernet (J204), 4-22

F Feedback Connections, 2-4, 2-7, 2-11, 2-18 Field Service Information, C-1 FireWire, 2-22, 3-23

Card and Cable Part Numbers, 2-20 Connector Pinouts, 3-23 J201, 2-22, 3-23 J202, 2-22, 3-23 J203, 2-22, 3-23

Index Ndrive HL Users Manual

Index-2 www.aerotech.com

Minimizing Cable Lengths, 2-21 Part Numbers, 2-20 Preferred Configuration, 2-21

FireWire Bus, 2-22, 3-23 FireWire:, 2-21 Fuse Replacement, 6-9

H Handwheel Interface, 5-9 Hardware Function, 1-3 Hardware Overview, 1-3 HCPL-2601, 4-15 High Inrush Currents, 1-4

I Input Power, 1-3

L1, L2, L3, 2-3 Main Supply, 2-3 Motor Frame Connections, 2-3, 2-4 Shield Connection, 2-3, 2-4 TB101, 2-3

Integrated, 2-4, 2-7 Integrated Configurations, 2-4, 2-7, 2-11, 2-

18 -IOPSO, 1-5, 4-11 IOPSO# option, 1-3 -IOPSO# Option

Jumpers, 5-1 -IOPSO# Option Board

Analog Inputs (TB302), 4-9 Analog Outputs, 4-3 Opto-Isolated Inputs (TB305), 4-12 PSO / Absolute Encoder Interface (J301),

4-14 -IOPSO2, 4-11 -IOPSO3, 4-11 -IOPSO4, 4-11

J J201

FireWire, 2-22, 3-23 J202

FireWire, 2-22, 3-23 J203

FireWire, 2-22, 3-23 J204, 4-22 J205

Connector Pinouts, 3-1, 3-3, 3-5, 3-6 J206

Connector Pinouts, 3-21 J206, 3-21 J207, 3-12, 4-3

Connector Pinouts, 3-12, 3-14, 3-15 J301, 4-14

Joystick Interface, 5-1, 5-5 JTAG, 6-8 JTAG Programming Connector, 6-8 Jumper Locations

Power Board, 6-5 Jumpers

Control Board, 6-3 -IOPSO#, 5-1 Power Board, 6-6

L AC1 Input Terminal, 2-3 AC2 Input Terminal, 2-3 Laser Output Opto-Isolator Specifications,

3-7, 4-15, 4-20 LED indicator, 1-3 LED Indicators

Description, 6-7 Limit and Hall Effect Inputs, 3-14 Line Driver Encoder (Standard), 3-16 Logic High, 2-10 Logic Low, 2-10

M Models, 1-5 Motor, 1-3 Motor and Feedback Connection Basic

Configurations, 2-7 Brushless, 2-7 DC Brush, 2-7 Stepper, 2-7

Motor and Feedback Connections, 2-4, 2-7, 2-11, 2-18

Motor Connections, 2-2, 2-4, 2-7, 2-11, 2-18 Motor Feedback

Connector Pinouts, 3-12, 3-14, 3-15 Motor Feedback, 3-12

MXH, 3-12 Motor Feedback

Connector, 4-3 Motor Frame Connection, 2-3, 2-4 Motor Phasing, 2-14, 2-15 -MXH, 1-5 -MXH Option

Specifications, 3-18 Clock Frequency, 3-18 Interpolation, 3-18 Max Input Frequency, 3-18 Minimum Edge Separation, 3-18 Minimum Pulse Width, 3-18

MXH, 3-12 Options, 3-17

MXH Analog Encoder Interface (Optional), 3-15, 3-16

Ndrive HL Users Manual Index

www.aerotech.com Index-3

N Ndrive Connection Test, 2-12 Ndrive Hardware, 1-3

O Optional AC Power Supply Input, 2-2 Optional Analog Input Connector Pinouts,

4-9 Options, 1-5 Opto-Isolated Input Connector

Pinouts, 4-12 Opto-Isolated Inputs (TB305), 4-12 Opto-Isolated Output Connector

Current Sinking Mode, 4-11 Current Sourcing Mode, 4-11

Output Current, Peak, 1-5

P P10, 6-8 Part Numbers

FireWire Card and Cables, 2-20 Phase/Hall Sequence, 2-12 Pinouts

Analog Output Connector, 4-3 Brake / Relay Connector, 4-5 Optional Analog Input Connector, 4-9 Opto-Isolated Input Connector, 4-12 PSO / Absolute Encoder Interface (J301),

4-14 SSINet (J302, J303), 4-17 User Power Connector, 4-10

Power, 1-5 Power Board, 6-4

Assembly, 6-4 Bus Voltage Jumper Selections, 6-5 Jumpers, 6-6 Line Voltage Jumper Selections, 6-5

Power Board Assembly, 6-5 Power Board Jumper Locations, 6-5 Power Board Options

-AUXPWR (Auxiliary Power), 1-5 Power Connections, 1-3, 2-2 Preventative Maintenance, 6-10 Product Overview, 1-2 PSO / Absolute Encoder Interface (J301), 4-

14 PSO / Absolute Encoder Interface (J301)

Pinouts, 4-14 PSO Connection, 1-3 -PSOOPTO1, 1-5, 4-15 -PSOOPTO2, 1-5, 4-15 -PSOOPTO3, 1-5, 4-15 -PSOOPTO4, 4-15

R Relay K1 Contact Ratings, 4-4 RS-232 Connector, 1-3 RS-232/RS-422, 3-21

Connector Pinouts, 3-21

S S2

Switch Settings, 2-19 Safety Procedures, 2-1 Shield Connection, 2-3, 2-4 Soft Start Circuit, 1-4 SSINet (J302, J303)

Pinouts, 4-17 Standard Encoder Input, 3-16 Standard Package, 1-4 Stepper Motor Configuration, 2-7, 2-14 Switch S2, 2-19

T Tachometer connection, 2-8 TB101, 2-2

AL1, 2-2 AL2, 2-2 Ground, 2-2 Optional AC Power Supply Input, 2-2

TB102, 2-3 TB301, 4-3 TB301 (Brake / Relay) Current

Specifications, 4-4 TB301 (Brake / Relay) Voltage

Specifications, 4-4 TB4, 4-9 TB7, 4-12 TIL117-M, 4-15 -TRIPLEPSO, 1-5 Troubleshooting, 6-1 Two Axis Laser Firing, 4-19 Typical ESTOP Interface, 2-6

U Unknown Phase/Hall Sequence, 2-12 User Power Connector Pinouts, 4-10

V Voltage configurations, 1-5

W Warnings, 2-1 Warranty Information, C-1

Index Ndrive HL Users Manual

Index-4 www.aerotech.com

∇ ∇ ∇

READERS COMMENTS Ndrive HL Users Manual P/N EDU176, October 31, 2007 Revision: 1.08b Please answer the questions below and add any suggestions for improving this document.

Is the manual:

Yes No Adequate to the subject

Well organized Clearly presented

Well illustrated How do you use this document in your job? Does it meet your needs? What improvements, if any, would you like to see? Please be specific or cite examples.

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Mail your comments to: or Fax to: AEROTECH, INC. Technical Writing Department 101 Zeta Drive Pittsburgh, PA. 15238 U.S.A.

412-967-6870

ndrive hl user's manual

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